Shock synthesized and static sintered boron nitride cutting tool

NASA Astrophysics Data System (ADS)

Araki, M.; Kuroyama, Y.

1986-05-01

Shock synthesis of wBN (wurtzite phase boron nitride) on an industrial scale was achieved by Nippon Oil & Fats and Showa Denko in 1971. It seemed that the resultant wBN powder might display excellent qualities as a cutting tool material when it was sintered under very high static pressure and temperature because of its polycrystalline nature. Attempts to produce a wBN cutting tool material were commenced by the Tokyo Institute of Technology and Nippon Oil & Fats in 1976 and commercially available wBN cutting tools were first sold in 1980. Meanwhile, a new type of explosion chamber designed to eliminate explosion sound and earth vibration problems, novel high pressure vessels and other peripheral apparatuses have been developed. Now, WURZIN (trademark for the wBN cutting tool) is used in many aspects of the steel cutting field because it is durable when cutting various steels from mild steels to superalloys under high speed, interrupt and precision cutting conditions.

Laser Cutting of Thin Nickel Bellows

NASA Technical Reports Server (NTRS)

Butler, C. L.

1986-01-01

Laser cutting technique produces narrow, precise, fast, and repeatable cuts in thin nickel-allow bellows material. Laser cutting operation uses intense focused beam to melt material and assisting gas to force melted material through part thickness, creating void. When part rotated or moved longitudinally, melting and material removal continuous and creates narrow, fast, precise, and repeatable cut. Technique used to produce cuts of specified depths less than material thickness. Avoids distortion, dents, and nicks produced in delicate materials during lathe trimming operations, which require high cutting-tool pressure and holding-fixture forces.

Vee-notch tool cuts specimens

NASA Technical Reports Server (NTRS)

Spier, R. A.

1970-01-01

Triangular cutting tool uses carbide tips for notching heat-treated or abrasive materials, and alloys subjected to high structural stresses. The tool is rigidly mounted in a slot of mating contour to prevent deflection during cutting of tensile specimens. No other expensive machine equipment is required.

Cutting holes in fabric-faced panels

NASA Technical Reports Server (NTRS)

Peterson, S. A.

1981-01-01

Tool has 2 carbide inserts that bore clean holes through fibrous material with knifelike slicing action. Cutting edge of insert is curved, with plane inner surface at 30 degree angle to tool axis. Drill press or hand-held drill can be used to hold cutting tool.

Wear of Cutting Tool with Excel Geometry in Turning Process of Hardened Steel

NASA Astrophysics Data System (ADS)

Samardžiová, Michaela

2016-09-01

This paper deals with hard turning using a cutting tool with Xcel geometry. This is one of the new geometries, and there is not any information about Xcel wear in comparison to the conventional geometry. It is already known from cutting tools producers that using the Xcel geometry leads to higher quality of machined surface, perticularly surface roughness. It is possible to achieve more than 4 times lower Ra and Rz values after turning than after using conventional geometry with radius. The workpiece material was 100Cr6 hardened steel with hardness of 60 ± 1 HRC. The machine used for the experiment was a lathe with counter spindle DMG CTX alpha 500, which is located in the Centre of Excellence of 5-axis Machining at the Faculty of Materials Science and Technology in Trnava. The cutting tools made by CBN were obtained from Sandvik COROMANT Company. The aim of this paper is to investigate the cutting tool wear in hard turning process by the Xcel cutting tool geometry.

Side Flow Effect on Surface Generation in Nano Cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-05-01

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius R s and stagnation height h s . The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} < 011>, {110} < 001>, and {110} < 1-10 > are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Side Flow Effect on Surface Generation in Nano Cutting.

PubMed

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius R s and stagnation height h s . The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} < 011>, {110} < 001>, and {110} < 1-10 > are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Laser assisted machining: a state of art review

NASA Astrophysics Data System (ADS)

Punugupati, Gurabvaiah; Kandi, Kishore Kumar; Bose, P. S. C.; Rao, C. S. P.

2016-09-01

Difficult-to-cut materials have increasing demand in aerospace and automobile industries due to their high yield stress, high strength to weight ratio, high toughness, high wear resistance, high creep, high corrosion resistivity, ability to retain high strength at high temperature, etc. The machinability of these advanced materials, using conventional methods of machining is typical due to the high temperature and pressure at the cutting zone and tool and properties such as low thermal conductivity, high cutting forces and cutting temperatures makes the materials difficult to machine. Laser assisted machining (LAM) is a new and innovative technique for machining the difficult-to-cut materials. This paper deals with a review on the advances in lasers, tools and the mechanism of machining using LAM and their effects.

An FMS Dynamic Production Scheduling Algorithm Considering Cutting Tool Failure and Cutting Tool Life

NASA Astrophysics Data System (ADS)

Setiawan, A.; Wangsaputra, R.; Martawirya, Y. Y.; Halim, A. H.

2016-02-01

This paper deals with Flexible Manufacturing System (FMS) production rescheduling due to unavailability of cutting tools caused either of cutting tool failure or life time limit. The FMS consists of parallel identical machines integrated with an automatic material handling system and it runs fully automatically. Each machine has a same cutting tool configuration that consists of different geometrical cutting tool types on each tool magazine. The job usually takes two stages. Each stage has sequential operations allocated to machines considering the cutting tool life. In the real situation, the cutting tool can fail before the cutting tool life is reached. The objective in this paper is to develop a dynamic scheduling algorithm when a cutting tool is broken during unmanned and a rescheduling needed. The algorithm consists of four steps. The first step is generating initial schedule, the second step is determination the cutting tool failure time, the third step is determination of system status at cutting tool failure time and the fourth step is the rescheduling for unfinished jobs. The approaches to solve the problem are complete-reactive scheduling and robust-proactive scheduling. The new schedules result differences starting time and completion time of each operations from the initial schedule.

Pressure-induced critical influences on workpiece-tool thermal interaction in high speed dry machining of titanium

NASA Astrophysics Data System (ADS)

Abdel-Aal, H. A.; Mansori, M. El

2012-12-01

Cutting tools are subject to extreme thermal and mechanical loads during operation. The state of loading is intensified in dry cutting environment especially when cutting the so called hard-to-cut-materials. Although, the effect of mechanical loads on tool failure have been extensively studied, detailed studies on the effect of thermal dissipation on the deterioration of the cutting tool are rather scarce. In this paper we study failure of coated carbide tools due to thermal loading. The study emphasizes the role assumed by the thermo-physical properties of the tool material in enhancing or preventing mass attrition of the cutting elements within the tool. It is shown that within a comprehensive view of the nature of conduction in the tool zone, thermal conduction is not solely affected by temperature. Rather it is a function of the so called thermodynamic forces. These are the stress, the strain, strain rate, rate of temperature rise, and the temperature gradient. Although that within such consideration description of thermal conduction is non-linear, it is beneficial to employ such a form because it facilitates a full mechanistic understanding of thermal activation of tool wear.

Microcutting characteristics on the single crystal diamond tool with edge radius using molecular dynamics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Jeong-Du; Moon, Chan-Hong

1995-12-31

Ultraprecision metal cutting (UPMC) technology which makes possible submicrometer form accuracy and manometer roughness is developed to reach the 1nm nominal (undeformed) thickness of cut. At this thickness level, a few of atom`s layers should be considered. In this paper using the Molecuar Dynamics simulation, the phenomena of microcutting with a subnanometer chip thickness, the cutting mechanism for tool edge configuration to consider the sharp edge and round edge tool, the cut material and cutting speed are evaluated. Cutting mechanism of subnanometer depth of cut is evaluated.

Finite Element Simulations of Micro Turning of Ti-6Al-4V using PCD and Coated Carbide tools

NASA Astrophysics Data System (ADS)

Jagadesh, Thangavel; Samuel, G. L.

2017-02-01

The demand for manufacturing axi-symmetric Ti-6Al-4V implants is increasing in biomedical applications and it involves micro turning process. To understand the micro turning process, in this work, a 3D finite element model has been developed for predicting the tool chip interface temperature, cutting, thrust and axial forces. Strain gradient effect has been included in the Johnson-Cook material model to represent the flow stress of the work material. To verify the simulation results, experiments have been conducted at four different feed rates and at three different cutting speeds. Since titanium alloy has low Young's modulus, spring back effect is predominant for higher edge radius coated carbide tool which leads to the increase in the forces. Whereas, polycrystalline diamond (PCD) tool has smaller edge radius that leads to lesser forces and decrease in tool chip interface temperature due to high thermal conductivity. Tool chip interface temperature increases by increasing the cutting speed, however the increase is less for PCD tool as compared to the coated carbide tool. When uncut chip thickness decreases, there is an increase in specific cutting energy due to material strengthening effects. Surface roughness is higher for coated carbide tool due to ploughing effect when compared with PCD tool. The average prediction error of finite element model for cutting and thrust forces are 11.45 and 14.87 % respectively.

Effect of cutting edge radius on surface roughness in diamond tool turning of transparent MgAl2O4 spinel ceramic

NASA Astrophysics Data System (ADS)

Yue, Xiaobin; Xu, Min; Du, Wenhao; Chu, Chong

2017-09-01

Transparent magnesium aluminate spinel (MgAl2O4) ceramic is one of an important optical materials. However, due to its pronounced hardness and brittleness, the optical machining of this material is very difficult. Diamond turning has advantages over the grinding process in flexibility and material removal rate. However, there is a lack of research that could support the use of diamond turning technology in the machining of MgAl2O4 spinel ceramic. Using brittle-ductile transition theory of brittle material machining, this work provides critical information that may help to realize ductile-regime turning of MgAl2O4 spinel ceramic. A characterization method of determination the cutting edge radius is introduced here. Suitable diamond tools were measured for sharpness and then chosen from a large number of candidate tools. The influence of rounded cutting edges on surface roughness of the MgAl2O4 spinel ceramic is also investigated. These results indicate that surface quality of MgAl2O4 spinel is relate to the radius of diamond tool's cutting edge, cutting speed, and feed rate. Sharp diamond tools (small radius of cutting edge) facilitated ductile-regime turning of MgAl2O4 spinel and shows great potential to reduce surface roughness and produce smoother final surface.

Effect of tool geometry and cutting parameters on delamination and thrust forces in drilling CFRP/Al-Li

NASA Astrophysics Data System (ADS)

El Bouami, Souhail; Habak, Malek; Franz, Gérald; Velasco, Raphaël; Vantomme, Pascal

2016-10-01

Composite materials are increasingly used for structural parts in the aeronautic industries. Carbon Fiber-Reinforced Plastics (CFRP) are often used in combination with metallic materials, mostly aluminium alloys. This raises new problems in aircraft assembly. Delamination is one of these problems. In this study, CFRP/Al-Li stacks is used as experimental material for investigation effect of interaction of cutting parameters (cutting speed and feed rate) and tool geometry on delamination and thrust forces in drilling operation. A plan of experiments, based on Taguchi design method, was employed to investigate the influence of tool geometry and in particular the point angle and cutting parameters on delamination and axial effort. The experimental results demonstrate that the feed rate is the major parameter and the importance of tool point angle in delamination and thrust forces in the stacks were shown.

Lathe tool bit and holder for machining fiberglass materials

NASA Technical Reports Server (NTRS)

Winn, L. E. (Inventor)

1972-01-01

A lathe tool and holder combination for machining resin impregnated fiberglass cloth laminates is described. The tool holder and tool bit combination is designed to accommodate a conventional carbide-tipped, round shank router bit as the cutting medium, and provides an infinite number of cutting angles in order to produce a true and smooth surface in the fiberglass material workpiece with every pass of the tool bit. The technique utilizes damaged router bits which ordinarily would be discarded.

Research Results Of Stress-Strain State Of Cutting Tool When Aviation Materials Turning

NASA Astrophysics Data System (ADS)

Serebrennikova, A. G.; Nikolaeva, E. P.; Savilov, A. V.; Timofeev, S. A.; Pyatykh, A. S.

2018-01-01

Titanium alloys and stainless steels are hard-to-machine of all the machining types. Cutting edge state of turning tool after machining titanium and high-strength aluminium alloys and corrosion-resistant high-alloy steel has been studied. Cutting forces and chip contact arears with the rake surface of cutter has been measured. The relationship of cutting forces and residual stresses are shown. Cutting forces and residual stresses vs value of cutting tool rake angle relation were obtained. Measurements of residual stresses were performed by x-ray diffraction.

The Effects of Cryogenic Treatment on Cutting Tools

NASA Astrophysics Data System (ADS)

Kumar, Satish; Khedkar, Nitin K.; Jagtap, Bhushan; Singh, T. P.

2017-08-01

Enhancing the cutting tool life is important and economic factor to reduce the tooling as well as manufacturing cost. The tool life is improved considerably by 92 % after cryogenic treatment. The cryogenic treatment is a one-time permanent, sub-zero heat treatment that entirely changes cross-section of cutting tool. The cryogenic treatment is carried out with deep freezing of cutting tool materials to enhance physical and mechanical properties. The cryogenic treatment improves mechanical such as hardness, toughness and tribological properties such as wear resistance, coefficient of friction, surface finish, dimensional stability and stress relief. The deep cryogenic treatment is the most beneficial treatment applied on cutting tools. The cryogenic treatment is the most advanced heat treatment and popular to improve performance of the cutting tool. The optimization of cryogenic treatment variables is necessary to improve tool life. This study reviews the effects of cryogenic treatment on microstructure, tribological properties of tool steels and machining applications of cutting tool by investigating the surface and performing the surface characterization test like SEM. The economy of cutting tool can be achieved by deep cryogenic treatment.

INTERNAL CUTTING DEVICE

DOEpatents

Russell, W.H. Jr.

1959-06-30

A device is described for removing material from the interior of a hollow workpiece so as to form a true spherical internal surface in a workpiece, or to cut radial slots of an adjustable constant depth in an already established spherical internal surface. This is accomplished by a spring loaded cutting tool adapted to move axially wherein the entire force urging the tool against the workpiece is derived from the spring. Further features of importance involve the provision of a seal between the workpiece and the cutting device and a suction device for carrying away particles of removed material.

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process.

PubMed

Dhandapani, N V; Thangarasu, V S; Sureshkannan, G

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results.

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process

PubMed Central

Dhandapani, N. V.; Thangarasu, V. S.; Sureshkannan, G.

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results. PMID:26881267

Laser cutting plastic materials

NASA Astrophysics Data System (ADS)

Vancleave, R. A.

1980-08-01

A 1000 watt CO2 laser was demonstrated as a reliable production machine tool for cutting of plastics, high strength reinforced composites, and other nonmetals. More than 40 different plastics were laser cut, and the results are tabulated. Applications for laser cutting described include fiberglass reinforced laminates, Kevlar/epoxy composites, fiberglass reinforced phenolics, nylon/epoxy laminates, ceramics, and disposal tooling made from acrylic.

Numerical modelling of orthogonal cutting: application to woodworking with a bench plane.

PubMed

Nairn, John A

2016-06-06

A numerical model for orthogonal cutting using the material point method was applied to woodcutting using a bench plane. The cutting process was modelled by accounting for surface energy associated with wood fracture toughness for crack growth parallel to the grain. By using damping to deal with dynamic crack propagation and modelling all contact between wood and the plane, simulations could initiate chip formation and proceed into steady-state chip propagation including chip curling. Once steady-state conditions were achieved, the cutting forces became constant and could be determined as a function of various simulation variables. The modelling details included a cutting tool, the tool's rake and grinding angles, a chip breaker, a base plate and a mouth opening between the base plate and the tool. The wood was modelled as an anisotropic elastic-plastic material. The simulations were verified by comparison to an analytical model and then used to conduct virtual experiments on wood planing. The virtual experiments showed interactions between depth of cut, chip breaker location and mouth opening. Additional simulations investigated the role of tool grinding angle, tool sharpness and friction.

An Analysis of the Effects of Chip-groove Geometry on Machining Performance Using Finite Element Methods

NASA Astrophysics Data System (ADS)

Ee, K. C.; Dillon, O. W.; Jawahir, I. S.

2004-06-01

This paper discusses the influence of major chip-groove parameters of a cutting tool on the chip formation process in orthogonal machining using finite element (FE) methods. In the FE formulation, a thermal elastic-viscoplastic material model is used together with a modified Johnson-Cook material law for the flow stress. The chip back-flow angle and the chip up-curl radius are calculated for a range of cutting conditions by varying the chip-groove parameters. The analysis provides greater understanding of the effectiveness of chip-groove configurations and points a way to correlate cutting conditions with tool-wear when machining with a grooved cutting tool.

Finite Element Simulation of Machining of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Rizzuti, S.; Umbrello, D.

2011-05-01

Titanium and its alloys are an important class of materials, especially for aerospace applications, due to their excellent combination of strength and fracture toughness as well as low density. However, these materials are generally regarded as difficult to machine because of their low thermal conductivity and high chemical reactivity with cutting tool materials. Moreover, the low thermal conductivity of Titanium inhibits dissipation of heat within the workpiece causing an higher temperature at the cutting edge and generating for higher cutting speed a rapid chipping at the cutting edge which leads to catastrophic failure. In addition, chip morphology significantly influences the thermo-mechanical behaviour at the workpiece/tool interface, which also affects the tool life. In this paper a finite element analysis of machining of TiAl6V4 is presented. In particular, cutting force, chip morphology and segmentation are taken into account due to their predominant roles to determine machinability and tool wear during the machining of these alloys. Results in terms of residual stresses are also presented. Moreover, the numerical results are compared with experimental ones.

2D simulations of orthogonal cutting of CFRP: Effect of tool angles on parameters of cut and chip morphology

NASA Astrophysics Data System (ADS)

Benhassine, Mehdi; Rivière-Lorphèvre, Edouard; Arrazola, Pedro-Jose; Gobin, Pierre; Dumas, David; Madhavan, Vinay; Aizpuru, Ohian; Ducobu, François

2018-05-01

Carbon-fiber reinforced composites (CFRP) are attractive materials for lightweight designs in applications needing good mechanical properties. Machining of such materials can be harder than metals due to their anisotropic behavior. In addition, the combination of the fibers and resin mechanical properties must also include the fiber orientation. In the case of orthogonal cutting, the tool inclination, rake angle or cutting angle usually influence the cutting process but such a detailed investigation is currently lacking in a 2D configuration. To address this issue, a model has been developed with Abaqus Explicit including Hashin damage. This model has been validated with experimental results from the literature. The effects of the tool parameters (rake angle, clearance angle) on the tool cutting forces, CFRP chip morphology and surface damage are herewith studied. It is shown that 90° orientation for the CFRP increases the surface damage. The rake angle has a minimal effect on the cutting forces but modifies the chip formation times. The feed forces are increased with increasing rake angle.

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

PubMed Central

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-01-01

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing. PMID:27854322

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining.

PubMed

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-11-16

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

Artificial Intelligence Based Selection of Optimal Cutting Tool and Process Parameters for Effective Turning and Milling Operations

NASA Astrophysics Data System (ADS)

Saranya, Kunaparaju; John Rozario Jegaraj, J.; Ramesh Kumar, Katta; Venkateshwara Rao, Ghanta

2016-06-01

With the increased trend in automation of modern manufacturing industry, the human intervention in routine, repetitive and data specific activities of manufacturing is greatly reduced. In this paper, an attempt has been made to reduce the human intervention in selection of optimal cutting tool and process parameters for metal cutting applications, using Artificial Intelligence techniques. Generally, the selection of appropriate cutting tool and parameters in metal cutting is carried out by experienced technician/cutting tool expert based on his knowledge base or extensive search from huge cutting tool database. The present proposed approach replaces the existing practice of physical search for tools from the databooks/tool catalogues with intelligent knowledge-based selection system. This system employs artificial intelligence based techniques such as artificial neural networks, fuzzy logic and genetic algorithm for decision making and optimization. This intelligence based optimal tool selection strategy is developed using Mathworks Matlab Version 7.11.0 and implemented. The cutting tool database was obtained from the tool catalogues of different tool manufacturers. This paper discusses in detail, the methodology and strategies employed for selection of appropriate cutting tool and optimization of process parameters based on multi-objective optimization criteria considering material removal rate, tool life and tool cost.

Analysis of Minimum Quantity Lubrication (MQL) for Different Coating Tools during Turning of TC11 Titanium Alloy.

PubMed

Qin, Sheng; Li, Zhongquan; Guo, Guoqiang; An, Qinglong; Chen, Ming; Ming, Weiwei

2016-09-28

The tool coating and cooling strategy are two key factors when machining difficult-to-cut materials such as titanium alloy. In this paper, diamond coating was deposited on a commercial carbide insert as an attempt to increase the machinability of TC11 alloy during the turning process. An uncoated carbide insert and a commercial Al₂O₃/TiAlN-coated tool were also tested as a comparison. Furthermore, MQL was applied to improve the cutting condition. Cutting performances were analyzed by cutting force, cutting temperate and surface roughness measurements. Tool wears and tool lives were evaluated to find a good matchup between the tool coating and cooling strategy. According to the results, using MQL can slightly reduce the cutting force. By applying MQL, cutting temperatures and tool wears were reduced by a great amount. Besides, MQL can affect the tool wear mechanism and tool failure modes. The tool life of an Al₂O₃/TiAlN-coated tool can be prolonged by 88.4% under the MQL condition. Diamond-coated tools can obtain a good surface finish when cutting parameters and lubrication strategies are properly chosen.

Analysis of Minimum Quantity Lubrication (MQL) for Different Coating Tools during Turning of TC11 Titanium Alloy

PubMed Central

Qin, Sheng; Li, Zhongquan; Guo, Guoqiang; An, Qinglong; Chen, Ming; Ming, Weiwei

2016-01-01

The tool coating and cooling strategy are two key factors when machining difficult-to-cut materials such as titanium alloy. In this paper, diamond coating was deposited on a commercial carbide insert as an attempt to increase the machinability of TC11 alloy during the turning process. An uncoated carbide insert and a commercial Al2O3/TiAlN-coated tool were also tested as a comparison. Furthermore, MQL was applied to improve the cutting condition. Cutting performances were analyzed by cutting force, cutting temperate and surface roughness measurements. Tool wears and tool lives were evaluated to find a good matchup between the tool coating and cooling strategy. According to the results, using MQL can slightly reduce the cutting force. By applying MQL, cutting temperatures and tool wears were reduced by a great amount. Besides, MQL can affect the tool wear mechanism and tool failure modes. The tool life of an Al2O3/TiAlN-coated tool can be prolonged by 88.4% under the MQL condition. Diamond-coated tools can obtain a good surface finish when cutting parameters and lubrication strategies are properly chosen. PMID:28773926

Tool wear of (Ti, Al) N-coated polycrystalline cubic boron nitride compact in cutting of hardened steel

NASA Astrophysics Data System (ADS)

Wada, Tadahiro; Hanyu, Hiroyuki

2017-11-01

Polycrystalline cubic boron nitride compact (cBN) is effective tool material for cutting hardened steel. In addition to coated high speed steel and coated cemented carbide that has long been used for cutting materials, more recently, coated cBN has also been used. In this study, to verify the effectiveness of the (Ti,Al)N-coated cBN, which is formed on the substrate of cBN by the physical vapor deposition method, the hardened steel was turned with the (Ti,Al)N-coated cBN tool at a cutting speed of 3.33, 5.00 m/s, a feed rate of 0.3 mm/rev and a depth of cut of 0.1 mm. Furthermore, the uncoated cBN, which was the substrate of the (Ti,Al)N-coated, was also used. The tool wear of the cBN tools was experimentally investigated. The following results were obtained: (1) The contact area between the rake face and the chip of the (Ti,.Al)N-coated cBN tool was smaller than that of the uncoated cBN tool. (2) The tool wear of the (Ti,Al)N-coated cBN was smaller than that of uncoated cBN. (3) The wear progress of the (Ti,Al)N-coated cBN with the main element phase of the TiCN-Al, was slower than that of the (Ti,Al)N-coated cBN with the main element phase of the TiN-Al. (4) In the case of the high cutting speed of 5.00 m/s, the tool wear of the (Ti,Al)N-coated cBN was also smaller than that of uncoated cBN. The above results clarify that the (Ti,Al)N-coated cBN can be used as a tool material in high feed cutting of hardened steel.

Drilling of CFRP and GFRP composite laminates using one shot solid carbide step drill K44

NASA Astrophysics Data System (ADS)

Nagaraja, R.; Rangaswamy, T.

2018-04-01

Drilling is a very common machining operation to install fasteners for assembly of laminates Drilling of Carbon Fiber Reinforced Plastic (CFRP) and Glass Fiber Reinforced Plastic (GFRP) composite laminate materials are different from that of convention materials that causes excessive tool wear and edge delamination. This paper reports on the tool geometry, cutting speed and feed rate. In this work two composite materials CFRP-G926 and Glass-7781 composite materials of varying thickness are drilled to investigate the effect of feed rate, and cutting speed. The study mainly focused on drilling laminates specimen of varying thickness 9 mm, 9.6 mm and 12 mm by using a single shot solid carbide step drill K44. The drilling is performed from lower to higher feed rate and cutting speed to investigate the hole quality, bottom top edge delamination, fiber breakages and local cracks. The work performed shows that a proper combination of tool geometry, cutting speed and feed rate can help to reduce the occurrence of delamination.

Trajectory Calculator for Finite-Radius Cutter on a Lathe

NASA Technical Reports Server (NTRS)

Savchenkov, Anatoliy; Strekalov, Dmitry; Yu, Nan

2009-01-01

A computer program calculates the two-dimensional trajectory (radial vs. axial position) of a finite-radius-of-curvature cutting tool on a lathe so as to cut a workpiece to a piecewise-continuous, analytically defined surface of revolution. (In the original intended application, the tool is a diamond cutter, and the workpiece is made of a crystalline material and is to be formed into an optical resonator disk.) The program also calculates an optimum cutting speed as F/L, where F is a material-dependent empirical factor and L is the effective instantaneous length of the cutting edge.

Experimental and numerical investigations on the temperature distribution in PVD AlTiN coated and uncoated Al2O3/TiCN mixed ceramic cutting tools in hard turning of AISI 52100 steel

NASA Astrophysics Data System (ADS)

Sateesh Kumar, Ch; Patel, Saroj Kumar; Das, Anshuman

2018-03-01

Temperature generation in cutting tools is one of the major causes of tool failure especially during hard machining where machining forces are quite high resulting in elevated temperatures. Thus, the present work investigates the temperature generation during hard machining of AISI 52100 steel (62 HRC hardness) with uncoated and PVD AlTiN coated Al2O3/TiCN mixed ceramic cutting tools. The experiments were performed on a heavy duty lathe machine with both coated and uncoated cutting tools under dry cutting environment. The temperature of the cutting zone was measured using an infrared thermometer and a finite element model has been adopted to predict the temperature distribution in cutting tools during machining for comparative assessment with the measured temperature. The experimental and numerical results revealed a significant reduction of cutting zone temperature during machining with PVD AlTiN coated cutting tools when compared to uncoated cutting tools during each experimental run. The main reason for decrease in temperature for AlTiN coated tools is the lower coefficient of friction offered by the coating material which allows the free flow of the chips on the rake surface when compared with uncoated cutting tools. Further, the superior wear behaviour of AlTiN coating resulted in reduction of cutting temperature.

Identification of Tool Wear when Machining of Austenitic Steels and Titatium by Miniature Machining

NASA Astrophysics Data System (ADS)

Pilc, Jozef; Kameník, Roman; Varga, Daniel; Martinček, Juraj; Sadilek, Marek

2016-12-01

Application of miniature machining is currently rapidly increasing mainly in biomedical industry and machining of hard-to-machine materials. Machinability of materials with increased level of toughness depends on factors that are important in the final state of surface integrity. Because of this, it is necessary to achieve high precision (varying in microns) in miniature machining. If we want to guarantee machining high precision, it is necessary to analyse tool wear intensity in direct interaction with given machined materials. During long-term cutting process, different cutting wedge deformations occur, leading in most cases to a rapid wear and destruction of the cutting wedge. This article deal with experimental monitoring of tool wear intensity during miniature machining.

Experimental investigation into effect of cutting parameters on surface integrity of hardened tool steel

NASA Astrophysics Data System (ADS)

Bashir, K.; Alkali, A. U.; Elmunafi, M. H. S.; Yusof, N. M.

2018-04-01

Recent trend in turning hardened materials have gained popularity because of its immense machinability benefits. However, several machining processes like thermal assisted machining and cryogenic machining have reveal superior machinability benefits over conventional dry turning of hardened materials. Various engineering materials have been studied. However, investigations on AISI O1 tool steel have not been widely reported. In this paper, surface finish and surface integrity dominant when hard turning AISI O1 tool steel is analysed. The study is focused on the performance of wiper coated ceramic tool with respect to surface roughness and surface integrity of hardened tool steel. Hard turned tool steel was machined at varying cutting speed of 100, 155 and 210 m/min and feed rate of 0.05, 0.125 and 0.20mm/rev. The depth of cut of 0.2mm was maintained constant throughout the machining trials. Machining was conducted using dry turning on 200E-axis CNC lathe. The experimental study revealed that the surface finish is relatively superior at higher cutting speed of 210m/min. The surface finish increases when cutting speed increases whereas surface finish is generally better at lower feed rate of 0.05mm/rev. The experimental study conducted have revealed that phenomena such as work piece vibration due to poor or improper mounting on the spindle also contributed to higher surface roughness value of 0.66Ra during turning at 0.2mm/rev. Traces of white layer was observed when viewed with optical microscope which shows evidence of cutting effects on the turned work material at feed rate of 0.2 rev/min

Microstructure, Mechanical and Wear Behaviors of Hot-Pressed Copper-Nickel-Based Materials for Diamond Cutting Tools

NASA Astrophysics Data System (ADS)

Miranda, G.; Ferreira, P.; Buciumeanu, M.; Cabral, A.; Fredel, M.; Silva, F. S.; Henriques, B.

2017-08-01

The current trend to replace cobalt in diamond cutting tools (DCT) for stone cutting has motivated the study of alternative materials for this end. The present study characterizes several copper-nickel-based materials (Cu-Ni; Cu-Ni-10Sn, Cu-Ni-15Sn, Cu-Ni-Sn-2WC and Cu-Ni-Sn-10WC) for using as matrix material for diamond cutting tools for stone. Copper-nickel-based materials were produced by hot pressing, at a temperature of 850 °C during 15 min and under an applied pressure of 50 MPa. The mechanical properties were evaluated though the shear strength and hardness values. The microstructures and fracture surfaces were analyzed by SEM. The wear behavior of all specimens was assessed using a reciprocating ball-on-plate tribometer. The hot pressing produced compacts with good densification. Sn and WC promoted enhanced mechanical properties and wear performance to Cu-Ni alloys. Cu-Ni-10Sn and Cu-Ni-10Sn-2WC displayed the best compromise between mechanical and wear performance.

Studies on nanosecond 532nm and 355nm and ultrafast 515nm and 532nm laser cutting super-hard materials

NASA Astrophysics Data System (ADS)

Zhang, Jie; Tao, Sha; Wang, Brian; Zhao, Jay

2017-02-01

In this paper, micro-processing of three kinds of super-hard materials of poly-crystal diamond (PCD)/tungsten-carbide (WC), CVD-diamond and cubic boron nitride (CNB) has been systematically studied using nanosecond laser (532nm and 355nm), and ultrafast laser (532nm and 515nm). Our purpose is to investigate a full laser micro-cutting solution to achieve a ready-to-use cutting tool insert (CTI). The results show a clean cut with little burns and recasting at edge. The cutting speed of 2-10mm/min depending on thickness was obtained. The laser ablation process was also studied by varying laser parameters (wavelength, pulse width, pulse energy, repetition rate) and tool path to improve cutting speed. Also, studies on material removal efficiency (MRE) of PCD/WC with 355nm-ns and 515nm-fs laser as a function of laser fluence show that 355nm-ns laser is able to achieve higher MRE for PCD and WC. Thus, ultrafast laser is not necessarily used for superhard material cutting. Instead, post-polishing with ultrafast laser can be used to clean cutting surface and improve smoothness.

Some aspects of precise laser machining - Part 1: Theory

NASA Astrophysics Data System (ADS)

Wyszynski, Dominik; Grabowski, Marcin; Lipiec, Piotr

2018-05-01

The paper describes the role of laser beam polarization and deflection on quality of laser beam machined parts made of difficult to cut materials (used for cutting tools). Application of efficient and precise cutting tool (laser beam) has significant impact on preparation and finishing operations of cutting tools for aviation part manufacturing. Understanding the phenomena occurring in the polarized light laser cutting gave possibility to design, build and test opto-mechanical instrumentation to control and maintain process parameters and conditions. The research was carried within INNOLOT program funded by Polish National Centre for Research and Development.

Robot based deposition of WC-Co HVOF coatings on HSS cutting tools as a substitution for solid cemented carbide cutting tools

NASA Astrophysics Data System (ADS)

Tillmann, W.; Schaak, C.; Biermann, D.; Aßmuth, R.; Goeke, S.

2017-03-01

Cemented carbide (hard metal) cutting tools are the first choice to machine hard materials or to conduct high performance cutting processes. Main advantages of cemented carbide cutting tools are their high wear resistance (hardness) and good high temperature strength. In contrast, cemented carbide cutting tools are characterized by a low toughness and generate higher production costs, especially due to limited resources. Usually, cemented carbide cutting tools are produced by means of powder metallurgical processes. Compared to conventional manufacturing routes, these processes are more expensive and only a limited number of geometries can be realized. Furthermore, post-processing and preparing the cutting edges in order to achieve high performance tools is often required. In the present paper, an alternative method to substitute solid cemented carbide cutting tools is presented. Cutting tools made of conventional high speed steels (HSS) were coated with thick WC-Co (88/12) layers by means of thermal spraying (HVOF). The challenge is to obtain a dense, homogenous, and near-net-shape coating on the flanks and the cutting edge. For this purpose, different coating strategies were realized using an industrial robot. The coating properties were subsequently investigated. After this initial step, the surfaces of the cutting tools were ground and selected cutting edges were prepared by means of wet abrasive jet machining to achieve a smooth and round micro shape. Machining tests were conducted with these coated, ground and prepared cutting tools. The occurring wear phenomena were analyzed and compared to conventional HSS cutting tools. Overall, the results of the experiments proved that the coating withstands mechanical stresses during machining. In the conducted experiments, the coated cutting tools showed less wear than conventional HSS cutting tools. With respect to the initial wear resistance, additional benefits can be obtained by preparing the cutting edge by means of wet abrasive jet machining.

Automated Laser Cutting In Three Dimensions

NASA Technical Reports Server (NTRS)

Bird, Lisa T.; Yvanovich, Mark A.; Angell, Terry R.; Bishop, Patricia J.; Dai, Weimin; Dobbs, Robert D.; He, Mingli; Minardi, Antonio; Shelton, Bret A.

1995-01-01

Computer-controlled machine-tool system uses laser beam assisted by directed flow of air to cut refractory materials into complex three-dimensional shapes. Velocity, position, and angle of cut varied. In original application, materials in question were thermally insulating thick blankets and tiles used on space shuttle. System shapes tile to concave or convex contours and cuts beveled edges on blanket, without cutting through outer layer of quartz fabric part of blanket. For safety, system entirely enclosed to prevent escape of laser energy. No dust generated during cutting operation - all material vaporized; larger solid chips dislodged from workpiece easily removed later.

Liquid Phase Sintering

NASA Technical Reports Server (NTRS)

2004-01-01

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Microgravity

NASA Image and Video Library

2004-04-15

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Key improvements in machining of Ti6al4v alloy: A review

NASA Astrophysics Data System (ADS)

Katta, Sivakoteswararao; Chaitanya, G.

2017-07-01

Now a days the use of ti-6al-4v alloy is high in demand in many industries like aero space, bio medical automobile, space, military etc. the production rates in the industries are not sufficient because the machiniability of ti-6al-4v is the main problem, there are several cutting tools available for metal cutting operations still there is a gap in finding the proper cutting tool material for machining of ti-6al-4v. because the properties of titanium like high heat resistant, low thermal conductivity, low weight ratio, less corrosiveness, and more many properties attracting the industrialists to use titanium as their material for their products, many researchers done the research on machininbility of ti-6al-4v by using different tool materials. but as for my literature survey there is still lot of scope is available, to find better cutting tool with techniques for machining ti-6al-4v. in this paper iam discussing the work done by various researchers on ti-6al-4v alloy with different techniques.

Comparison of tool life and surface roughness with MQL, flood cooling, and dry cutting conditions with P20 and D2 steel

NASA Astrophysics Data System (ADS)

Senevirathne, S. W. M. A. I.; Punchihewa, H. K. G.

2017-09-01

Minimum quantity lubrication (MQL) is a cutting fluid (CF) application method that has given promising results in improving machining performances. It has shown that, the performance of cutting systems, depends on the work and tool materials used. AISI P20, and D2 are popular in tool making industry. However, the applicability of MQL in machining these two steels has not been studied previously. This experimental study is focused on evaluating performances of MQL compared to dry cutting, and conventional flood cooling method. Trials were carried out with P20, and D2 steels, using coated carbides as tool material, emulsion cutting oil as the CF. Tool nose wear, and arithmetic average surface roughness (Ra) were taken as response variables. Results were statistically analysed for differences in response variables. Although many past literature has suggested that MQL causes improvements in tool wear, and surface finish, this study has found contradicting results. MQL has caused nearly 200% increase in tool nose wear, and nearly 11-13% increase in surface roughness compared flood cooling method with both P20 and D2. Therefore, this study concludes that MQL affects adversely in machining P20, and D2 steels.

The Tool Life of Ball Nose end Mill Depending on the Different Types of Ramping

NASA Astrophysics Data System (ADS)

Vopát, Tomáš; Peterka, Jozef; Kováč, Martin

2014-12-01

The article deals with the cutting tool wear measurement process and tool life of ball nose end mill depending on upward ramping and downward ramping. The aim was to determine and compare the wear (tool life) of ball nose end mill for different types of copy milling operations, as well as to specify particular steps of the measurement process. In addition, we examined and observed cutter contact areas of ball nose end mill with machined material. For tool life test, DMG DMU 85 monoBLOCK 5-axis CNC milling machine was used. In the experiment, cutting speed, feed rate, axial depth of cut and radial depth of cut were not changed. The cutting tool wear was measured on Zoller Genius 3s universal measuring machine. The results show different tool life of ball nose end mills depending on the copy milling strategy.

Toolpath strategy for cutter life improvement in plunge milling of AISI H13 tool steel

NASA Astrophysics Data System (ADS)

Adesta, E. Y. T.; Avicenna; hilmy, I.; Daud, M. R. H. C.

2018-01-01

Machinability of AISI H13 tool steel is a prominent issue since the material has the characteristics of high hardenability, excellent wear resistance, and hot toughness. A method of improving cutter life of AISI H13 tool steel plunge milling by alternating the toolpath and cutting conditions is proposed. Taguchi orthogonal array with L9 (3^4) resolution will be employed with one categorical factor of toolpath strategy (TS) and three numeric factors of cutting speed (Vc), radial depth of cut (ae ), and chip load (fz ). It is expected that there are significant differences for each application of toolpath strategy and each cutting condition factor toward the cutting force and tool wear mechanism of the machining process, and medial axis transform toolpath could provide a better tool life improvement by a reduction of cutting force during machining.

High speed turning of compacted graphite iron using controlled modulation

NASA Astrophysics Data System (ADS)

Stalbaum, Tyler Paul

Compacted graphite iron (CGI) is a material which emerged as a candidate material to replace cast iron (CI) in the automotive industry for engine block castings. Its thermal and mechanical properties allow the CGI-based engines to operate at higher cylinder pressures and temperatures than CI-based engines, allowing for lower fuel emissions and increased fuel economy. However, these same properties together with the thermomechanical wear mode in the CGI-CBN system result in poor machinability and inhibit CGI from seeing wide spread use in the automotive industry. In industry, machining of CGI is done only at low speeds, less than V = 200 m/min, to avoid encountering rapid wear of the cutting tools during cutting. Studies have suggested intermittent cutting operations such as milling suffer less severe tool wear than continuous cutting. Furthermore, evidence that a hard sulfide layer which forms over the cutting edge in machining CI at high speeds is absent during machining CGI is a major factor in the difference in machinability of these material systems. The present study addresses both of these issues by modification to the conventional machining process to allow intermittent continuous cutting. The application of controlled modulation superimposed onto the cutting process -- modulation-assisted machining (MAM) -- is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining CGI at high machining speeds (> 500 m/min). The tool life is at least 20 times greater than found in conventional machining of CGI. This significant reduction in wear is a consequence of reduction in the severity of the tool-work contact conditions with MAM. The propensity for thermochemical wear of CBN is thus reduced. It is found that higher cutting speed (> 700 m/min) leads to lower tool wear with MAM. The MAM configuration employing feed-direction modulation appears feasible for implementation at high speeds and offers a solution to this challenging class of industrial machining applications. This study's approach is by series of high speed turning tests of CGI with CBN tools, comparing conventional machining to MAM for similar parameters otherwise, by tool wear measurements and machinability observations.

Simulation of router action on a lathe to test the cutting tool performance in edge-trimming of graphite/epoxy composite

NASA Astrophysics Data System (ADS)

Ramulu, M.; Rogers, E.

1994-04-01

The predominant machining application with graphite/epoxy composite materials in aerospace industry is peripheral trimming. The computer numerically controlled (CNC) high speed routers required to do edge trimming work are generally scheduled for production work in industry and are not available for extensive cutter testing. Therefore, an experimental method of simulating the conditions of periphery trim using a lathe is developed in this paper. The validity of the test technique will be demonstrated by conducting carbide tool wear tests under dry cutting conditions. The experimental results will be analyzed to characterize the wear behavior of carbide cutting tools in machining the composite materials.

The Impact Of Surface Shape Of Chip-Breaker On Machined Surface

NASA Astrophysics Data System (ADS)

Šajgalík, Michal; Czán, Andrej; Martinček, Juraj; Varga, Daniel; Hemžský, Pavel; Pitela, David

2015-12-01

Machined surface is one of the most used indicators of workpiece quality. But machined surface is influenced by several factors such as cutting parameters, cutting material, shape of cutting tool or cutting insert, micro-structure of machined material and other known as technological parameters. By improving of these parameters, we can improve machined surface. In the machining, there is important to identify the characteristics of main product of these processes - workpiece, but also the byproduct - the chip. Size and shape of chip has impact on lifetime of cutting tools and its inappropriate form can influence the machine functionality and lifetime, too. This article deals with elimination of long chip created when machining of shaft in automotive industry and with impact of shape of chip-breaker on shape of chip in various cutting conditions based on production requirements.

Is fracture a bigger problem for smaller animals? Force and fracture scaling for a simple model of cutting, puncture and crushing

PubMed Central

Choi, Seunghee; Coon, Joshua J.; Goggans, Matthew Scott; Kreisman, Thomas F.; Silver, Daniel M.; Nesson, Michael H.

2016-01-01

Many of the materials that are challenging for large animals to cut or puncture are also cut and punctured by much smaller organisms that are limited to much smaller forces. Small organisms can overcome their force limitations by using sharper tools, but one drawback may be an increased susceptibility to fracture. We use simple contact mechanics models to estimate how much smaller the diameter of the tips or edges of tools such as teeth, claws and cutting blades must be in smaller organisms in order for them to puncture or cut the same materials as larger organisms. In order to produce the same maximum stress when maximum force scales as the square of body length, the diameter of the tool region that is in contact with the target material must scale isometrically for punch-like tools (e.g. scorpion stings) on thick targets, and for crushing tools (e.g. molars). For punch-like tools on thin targets, and for cutting blades on thick targets, the tip or edge diameters must be even smaller than expected from isometry in smaller animals. The diameters of a small sample of unworn punch-like tools from a large range of animal sizes are consistent with the model, scaling isometrically or more steeply (positively allometric). In addition, we find that the force required to puncture a thin target using real biological tools scales linearly with tip diameter, as predicted by the model. We argue that, for smaller tools, the minimum energy to fracture the tool will be a greater fraction of the minimum energy required to puncture the target, making fracture more likely. Finally, energy stored in tool bending, relative to the energy to fracture the tool, increases rapidly with the aspect ratio (length/width), and we expect that smaller organisms often have to employ higher aspect ratio tools in order to puncture or cut to the required depth with available force. The extra stored energy in higher aspect ratio tools is likely to increase the probability of fracture. We discuss some of the implications of the suggested scaling rules and possible adaptations to compensate for fracture sensitivity in smaller organisms. PMID:27274804

An experimental study of flank wear in the end milling of AISI 316 stainless steel with coated carbide inserts

NASA Astrophysics Data System (ADS)

Odedeyi, P. B.; Abou-El-Hossein, K.; Liman, M.

2017-05-01

Stainless steel 316 is a difficult-to-machine iron-based alloys that contain minimum of about 12% of chromium commonly used in marine and aerospace industry. This paper presents an experimental study of the tool wear propagation variations in the end milling of stainless steel 316 with coated carbide inserts. The milling tests were conducted at three different cutting speeds while feed rate and depth of cut were at (0.02, 0.06 and 01) mm/rev and (1, 2 and 3) mm, respectively. The cutting tool used was TiAlN-PVD-multi-layered coated carbides. The effects of cutting speed, cutting tool coating top layer and workpiece material were investigated on the tool life. The results showed that cutting speed significantly affected the machined flank wears values. With increasing cutting speed, the flank wear values decreased. The experimental results showed that significant flank wear was the major and predominant failure mode affecting the tool life.

Precision machining of advanced materials with waterjets

NASA Astrophysics Data System (ADS)

Liu, H. T.

2017-01-01

Recent advances in abrasive waterjet technology have elevated to the state that it often competes on equal footing with lasers and EDM for precision machining. Under the support of a National Science Foundation SBIR Phase II grant, OMAX has developed and commercialized micro abrasive water technology that is incorporated into a MicroMAX® JetMa- chining® Center. Waterjet technology, combined both abrasive waterjet and micro abrasive waterjet technology, is capable of machining most materials from macro to micro scales for a wide range of part size and thickness. Waterjet technology has technological and manufacturing merits that cannot be matched by most existing tools. As a cold cutting tool that creates no heat-affected zone, for example, waterjet cuts much faster than wire EDM and laser when measures to minimize a heat-affected zone are taken into account. In addition, waterjet is material independent; it cuts materials that cannot be cut or are difficult to cut otherwise. The versatility of waterjet has also demonstrated machining simulated nanomaterials with large gradients of material properties from metal, nonmetal, to anything in between. This paper presents waterjet-machined samples made of a wide range of advanced materials from macro to micro scales.

Surface topography and roughness of high-speed milled AlMn1Cu

NASA Astrophysics Data System (ADS)

Wang, Zhenhua; Yuan, Juntang; Yin, Zengbin; Hu, Xiaoqiu

2016-10-01

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope(SEM). The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters (e.g. cutting speed, feed per tooth and depth of cut) influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.

Ultrasonically assisted turning of aviation materials: simulations and experimental study.

PubMed

Babitsky, V I; Mitrofanov, A V; Silberschmidt, V V

2004-04-01

Ultrasonically assisted turning of modern aviation materials is conducted with ultrasonic vibration (frequency f approximately 20 kHz, amplitude a approximately 15 microm) superimposed on the cutting tool movement. An autoresonant control system is used to maintain the stable nonlinear resonant mode of vibration throughout the cutting process. Experimental comparison of roughness and roundness for workpieces machined conventionally and with the superimposed ultrasonic vibration, results of high-speed filming of the turning process and nanoindentation analyses of the microstructure of the machined material are presented. The suggested finite-element model provides numerical comparison between conventional and ultrasonic turning of Inconel 718 in terms of stress/strain state, cutting forces and contact conditions at the workpiece/tool interface.

Application of dynamic milling in stainless steel processing

NASA Astrophysics Data System (ADS)

Shan, Wenju

2017-09-01

This paper mainly introduces the method of parameter setting for NC programming of stainless steel parts by dynamic milling. Stainless steel is of high plasticity and toughness, serious hard working, large cutting force, high temperature in cutting area and easy wear of tool. It is difficult to process material. Dynamic motion technology is the newest NC programming technology of Mastercam software. It is an advanced machining idea. The tool path generated by the dynamic motion technology is more smooth, more efficient and more stable in the machining process. Dynamic motion technology is very suitable for cutting hard machining materials.

Cutting Symmetrical Recesses In Soft Ceramic Tiles

NASA Technical Reports Server (NTRS)

Nesotas, Tony C.; Tyler, Brent

1989-01-01

Simple tool cuts hemispherical recesses in soft ceramic tiles. Designed to expose wires of thermocouples embedded in tiles without damaging leads. Creates neat, precise holes around wires. End mill includes axial hole to accommodate thermocouple wires embedded in material to be cut. Wires pass into hole without being bent or broken. Dimensions in inches. Used in place of such tools as dental picks, tweezers, spatulas, and putty knives.

Digital modeling of end-mill cutting tools for FEM applications from the active cutting contour

NASA Astrophysics Data System (ADS)

Salguero, Jorge; Marcos, M.; Batista, M.; Gómez, A.; Mayuet, P.; Bienvenido, R.

2012-04-01

A very current technique in the research field of machining by material removal is the use of simulations using the Finite Element Method (FEM). Nevertheless, and although is widely used in processes that allows approximations to orthogonal cutting, such as shaping, is scarcely used in more complexes processes, such as milling. This fact is due principally to the complex geometry of the cutting tools in these processes, and the need to realize the studi es in an oblique cutting configuration. This paper shows a methodology for the geometrical characterization of commercial endmill cutting tools, by the extraction of the cutting tool contour, making use of optical metrology, and using this geometry to model the active cutting zone with a 3D CAD software. This model is easily exportable to different CAD formats, such as IGES or STEP, and importable from FEM software, where is possible to study the behavior in service of the same ones.

Surface grinding of space materials using specially formulated vitrified grinding wheels

NASA Astrophysics Data System (ADS)

Jackson, M. J.; Robinson, G.

2006-04-01

The quantum leap that is expected in the reliability and safety of machined engineering components over the next 20 years, especially in the space industries, will require improvements in the quality of cutting tools if science-based manufacturing is the goal for manufacturing by 2020. Significant improvements have been made in the past 10 years by understanding the properties of vitrified bonding systems used to bond conventional and superabrasive materials in grinding tools. The nature of the bonding system is of paramount importance if next-generation cutting tools are to be used for aerospace materials, especially if they are dressed using laser beams.

Method for forming an abrasive surface on a tool

DOEpatents

Seals, Roland D.; White, Rickey L.; Swindeman, Catherine J.; Kahl, W. Keith

1999-01-01

A method for fabricating a tool used in cutting, grinding and machining operations, is provided. The method is used to deposit a mixture comprising an abrasive material and a bonding material on a tool surface. The materials are propelled toward the receiving surface of the tool substrate using a thermal spray process. The thermal spray process melts the bonding material portion of the mixture, but not the abrasive material. Upon impacting the tool surface, the mixture or composition solidifies to form a hard abrasive tool coating.

Chatter active control in a lathe machine using magnetostrictive actuator

NASA Astrophysics Data System (ADS)

Nosouhi, R.; Behbahani, S.

2011-01-01

This paper analyzes the chatter phenomena in lathe machines. Chatter is one of the main causes of inaccuracy, reduction of life cycle of the machine and tool wear in machine tools. This phenomenon limits the depth of cut as a function of the cutting speed, which consequently reduces the material removal rate and machining efficiency. Chatter control is therefore important since it increases the stability region in machining and increases the critical depth of cut in machining case. To control the chatter in lathe machines, a magnetostrictive actuator is used. The materials with magnetostriction properties are kind of smart materials of which their length changes as a result of applying an exterior magnetic field, which make them suitable for control applications. It is assumed that the actuator applies the proper force exactly at the point where the machining force is applied on the tool. In this paper the chatter stability lobes is excelled as a result of applying a PID controller on the magnetostrictive actuator equipped-tool in turning.

Modeling of the flow stress for AISI H13 Tool Steel during Hard Machining Processes

NASA Astrophysics Data System (ADS)

Umbrello, Domenico; Rizzuti, Stefania; Outeiro, José C.; Shivpuri, Rajiv

2007-04-01

In general, the flow stress models used in computer simulation of machining processes are a function of effective strain, effective strain rate and temperature developed during the cutting process. However, these models do not adequately describe the material behavior in hard machining, where a range of material hardness between 45 and 60 HRC are used. Thus, depending on the specific material hardness different material models must be used in modeling the cutting process. This paper describes the development of a hardness-based flow stress and fracture models for the AISI H13 tool steel, which can be applied for range of material hardness mentioned above. These models were implemented in a non-isothermal viscoplastic numerical model to simulate the machining process for AISI H13 with various hardness values and applying different cutting regime parameters. Predicted results are validated by comparing them with experimental results found in the literature. They are found to predict reasonably well the cutting forces as well as the change in chip morphology from continuous to segmented chip as the material hardness change.

Hard particle effect on surface generation in nano-cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhang, Xiaodong

2017-12-01

The influence of the hard particle on the surface generation, plastic deformation and processing forces in nano-cutting of aluminum is investigated by means of molecular dynamics simulations. In this investigation, a hard particle which is simplified as a diamond ball is embedded under the free surface of workpiece with different depths. The influence of the position of the hard ball on the surface generation and other material removal mechanism, such as the movement of the ball under the action of cutting tool edge, is revealed. The results show that when the hard particle is removed, only a small shallow pit is left on the machined surface. Otherwise, it is pressed down to the subsurface of the workpiece left larger and deeper pit on the generated surface. Besides that, the hard particle in the workpiece would increase the processing force when the cutting tool edge or the plastic carriers interact with the hard particle. It is helpful to optimize the cutting parameters and material properties for obtaining better surface quality in nano-cutting of composites or other materials with micro/nanoscale hard particles in it.

Prediction of Cutting Force in Turning Process-an Experimental Approach

NASA Astrophysics Data System (ADS)

Thangarasu, S. K.; Shankar, S.; Thomas, A. Tony; Sridhar, G.

2018-02-01

This Paper deals with a prediction of Cutting forces in a turning process. The turning process with advanced cutting tool has a several advantages over grinding such as short cycle time, process flexibility, compatible surface roughness, high material removal rate and less environment problems without the use of cutting fluid. In this a full bridge dynamometer has been used to measure the cutting forces over mild steel work piece and cemented carbide insert tool for different combination of cutting speed, feed rate and depth of cut. The experiments are planned based on taguchi design and measured cutting forces were compared with the predicted forces in order to validate the feasibility of the proposed design. The percentage contribution of each process parameter had been analyzed using Analysis of Variance (ANOVA). Both the experimental results taken from the lathe tool dynamometer and the designed full bridge dynamometer were analyzed using Taguchi design of experiment and Analysis of Variance.

Force Modelling in Orthogonal Cutting Considering Flank Wear Effect

NASA Astrophysics Data System (ADS)

Rathod, Kanti Bhikhubhai; Lalwani, Devdas I.

2017-05-01

In the present work, an attempt has been made to provide a predictive cutting force model during orthogonal cutting by combining two different force models, that is, a force model for a perfectly sharp tool plus considering the effect of edge radius and a force model for a worn tool. The first force model is for a perfectly sharp tool that is based on Oxley's predictive machining theory for orthogonal cutting as the Oxley's model is for perfectly sharp tool, the effect of cutting edge radius (hone radius) is added and improve model is presented. The second force model is based on worn tool (flank wear) that was proposed by Waldorf. Further, the developed combined force model is also used to predict flank wear width using inverse approach. The performance of the developed combined total force model is compared with the previously published results for AISI 1045 and AISI 4142 materials and found reasonably good agreement.

Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools

NASA Astrophysics Data System (ADS)

López de Lacalle, Luis Norberto; Urbicain Pelayo, Gorka; Fernández-Valdivielso, Asier; Alvarez, Alvaro; González, Haizea

2017-09-01

Difficult to cut materials such as nickel and titanium alloys are used in the aeronautical industry, the former alloys due to its heat-resistant behavior and the latter for the low weight - high strength ratio. Ceramic tools made out alumina with reinforce SiC whiskers are a choice in turning for roughing and semifinishing workpiece stages. Wear rate is high in the machining of these alloys, and consequently cutting forces tends to increase along one operation. This paper establishes the cutting force relation between work-piece and tool in the turning of such difficult-to-cut alloys by means of a mechanistic cutting force model that considers the tool wear effect. The cutting force model demonstrates the force sensitivity to the cutting engagement parameters (ap, f) when using ceramic inserts and wear is considered. Wear is introduced through a cutting time factor, being useful in real conditions taking into account that wear quickly appears in alloys machining. A good accuracy in the cutting force model coefficients is the key issue for an accurate prediction of turning forces, which could be used as criteria for tool replacement or as input for chatter or other models.

Molecular dynamic simulation for nanometric cutting of single-crystal face-centered cubic metals.

PubMed

Huang, Yanhua; Zong, Wenjun

2014-01-01

In this work, molecular dynamics simulations are performed to investigate the influence of material properties on the nanometric cutting of single crystal copper and aluminum with a diamond cutting tool. The atomic interactions in the two metallic materials are modeled by two sets of embedded atom method (EAM) potential parameters. Simulation results show that although the plastic deformation of the two materials is achieved by dislocation activities, the deformation behavior and related physical phenomena, such as the machining forces, machined surface quality, and chip morphology, are significantly different for different materials. Furthermore, the influence of material properties on the nanometric cutting has a strong dependence on the operating temperature.

On the closed form mechanistic modeling of milling: Specific cutting energy, torque, and power

NASA Astrophysics Data System (ADS)

Bayoumi, A. E.; Yücesan, G.; Hutton, D. V.

1994-02-01

Specific energy in metal cutting, defined as the energy expended in removing a unit volume of workpiece material, is formulated and determined using a previously developed closed form mechanistic force model for milling operations. Cutting power is computed from the cutting torque, cutting force, kinematics of the cutter, and the volumetric material removal rate. Closed form expressions for specific cutting energy were formulated and found to be functions of the process parameters: pressure and friction for both rake and flank surfaces and chip flow angle at the rake face of the tool. Friction is found to play a very important role in cutting torque and power. Experiments were carried out to determine the effects of feedrate, cutting speed, workpiece material, and flank wear land width on specific cutting energy. It was found that the specific cutting energy increases with a decrease in the chip thickness and with an increase in flank wear land.

Thermocouple and infrared sensor-based measurement of temperature distribution in metal cutting.

PubMed

Kus, Abdil; Isik, Yahya; Cakir, M Cemal; Coşkun, Salih; Özdemir, Kadir

2015-01-12

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

PubMed Central

Kus, Abdil; Isik, Yahya; Cakir, M. Cemal; Coşkun, Salih; Özdemir, Kadir

2015-01-01

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining. PMID:25587976

Influence of Fiber Orientation on Single-Point Cutting Fracture Behavior of Carbon-Fiber/Epoxy Prepreg Sheets.

PubMed

Wei, Yingying; An, Qinglong; Cai, Xiaojiang; Chen, Ming; Ming, Weiwei

2015-10-02

The purpose of this article is to investigate the influences of carbon fibers on the fracture mechanism of carbon fibers both in macroscopic view and microscopic view by using single-point flying cutting method. Cutting tools with three different materials were used in this research, namely, PCD (polycrystalline diamond) tool, CVD (chemical vapor deposition) diamond thin film coated carbide tool and uncoated carbide tool. The influence of fiber orientation on the cutting force and fracture topography were analyzed and conclusions were drawn that cutting forces are not affected by cutting speeds but significantly influenced by the fiber orientation. Cutting forces presented smaller values in the fiber orientation of 0/180° and 15/165° but the highest one in 30/150°. The fracture mechanism of carbon fibers was studied in different cutting conditions such as 0° orientation angle, 90° orientation angle, orientation angles along fiber direction, and orientation angles inverse to the fiber direction. In addition, a prediction model on the cutting defects of carbon fiber reinforced plastic was established based on acoustic emission (AE) signals.

Influence of Fiber Orientation on Single-Point Cutting Fracture Behavior of Carbon-Fiber/Epoxy Prepreg Sheets

PubMed Central

Wei, Yingying; An, Qinglong; Cai, Xiaojiang; Chen, Ming; Ming, Weiwei

2015-01-01

The purpose of this article is to investigate the influences of carbon fibers on the fracture mechanism of carbon fibers both in macroscopic view and microscopic view by using single-point flying cutting method. Cutting tools with three different materials were used in this research, namely, PCD (polycrystalline diamond) tool, CVD (chemical vapor deposition) diamond thin film coated carbide tool and uncoated carbide tool. The influence of fiber orientation on the cutting force and fracture topography were analyzed and conclusions were drawn that cutting forces are not affected by cutting speeds but significantly influenced by the fiber orientation. Cutting forces presented smaller values in the fiber orientation of 0/180° and 15/165° but the highest one in 30/150°. The fracture mechanism of carbon fibers was studied in different cutting conditions such as 0° orientation angle, 90° orientation angle, orientation angles along fiber direction, and orientation angles inverse to the fiber direction. In addition, a prediction model on the cutting defects of carbon fiber reinforced plastic was established based on acoustic emission (AE) signals. PMID:28793597

Atomistic aspects of ductile responses of cubic silicon carbide during nanometric cutting

PubMed Central

2011-01-01

Cubic silicon carbide (SiC) is an extremely hard and brittle material having unique blend of material properties which makes it suitable candidate for microelectromechanical systems and nanoelectromechanical systems applications. Although, SiC can be machined in ductile regime at nanoscale through single-point diamond turning process, the root cause of the ductile response of SiC has not been understood yet which impedes significant exploitation of this ceramic material. In this paper, molecular dynamics simulation has been carried out to investigate the atomistic aspects of ductile response of SiC during nanometric cutting process. Simulation results show that cubic SiC undergoes sp3-sp2 order-disorder transition resulting in the formation of SiC-graphene-like substance with a growth rate dependent on the cutting conditions. The disorder transition of SiC causes the ductile response during its nanometric cutting operations. It was further found out that the continuous abrasive action between the diamond tool and SiC causes simultaneous sp3-sp2 order-disorder transition of diamond tool which results in graphitization of diamond and consequent tool wear. PMID:22078069

Atomistic aspects of ductile responses of cubic silicon carbide during nanometric cutting.

PubMed

Goel, Saurav; Luo, Xichun; Reuben, Robert L; Rashid, Waleed Bin

2011-11-11

Cubic silicon carbide (SiC) is an extremely hard and brittle material having unique blend of material properties which makes it suitable candidate for microelectromechanical systems and nanoelectromechanical systems applications. Although, SiC can be machined in ductile regime at nanoscale through single-point diamond turning process, the root cause of the ductile response of SiC has not been understood yet which impedes significant exploitation of this ceramic material. In this paper, molecular dynamics simulation has been carried out to investigate the atomistic aspects of ductile response of SiC during nanometric cutting process. Simulation results show that cubic SiC undergoes sp3-sp2 order-disorder transition resulting in the formation of SiC-graphene-like substance with a growth rate dependent on the cutting conditions. The disorder transition of SiC causes the ductile response during its nanometric cutting operations. It was further found out that the continuous abrasive action between the diamond tool and SiC causes simultaneous sp3-sp2 order-disorder transition of diamond tool which results in graphitization of diamond and consequent tool wear.

Effects of Ultrasonics-Assisted Face Milling on Surface Integrity and Fatigue Life of Ni-Alloy 718

NASA Astrophysics Data System (ADS)

Suárez, Alfredo; Veiga, Fernando; de Lacalle, Luis N. López; Polvorosa, Roberto; Lutze, Steffen; Wretland, Anders

2016-11-01

This work investigates the effects of ultrasonic vibration-assisted milling on important aspects such us material surface integrity, tool wear, cutting forces and fatigue resistance. As an alternative to natural application of ultrasonic milling in brittle materials, in this study, ultrasonics have been applied to a difficult-to-cut material, Alloy 718, very common in high-temperature applications. Results show alterations in the sub-superficial part of the material which could influence fatigue resistance of the material, as it has been observed in a fatigue test campaign of specimens obtained with the application of ultrasonic milling in comparison with another batch obtained applying conventional milling. Tool wear pattern was found to be very similar for both milling technologies, concluding the study with the analysis of cutting forces, exhibiting certain improvement in case of the application of ultrasonic milling with a more stable evolution.

Laser beam machining of polycrystalline diamond for cutting tool manufacturing

NASA Astrophysics Data System (ADS)

Wyszyński, Dominik; Ostrowski, Robert; Zwolak, Marek; Bryk, Witold

2017-10-01

The paper concerns application of DPSS Nd: YAG 532nm pulse laser source for machining of polycrystalline WC based diamond inserts (PCD). The goal of the research was to determine optimal laser cutting parameters for cutting tool shaping. Basic criteria to reach the goal was cutting edge quality (minimalization of finishing operations), material removal rate (time and cost efficiency), choice of laser beam characteristics (polarization, power, focused beam diameter). The research was planned and realised and analysed according to design of experiment rules (DOE). The analysis of the cutting edge was prepared with use of Alicona Infinite Focus measurement system.

Producing Fe-W-Co-Cr-C Alloy Cutting Tool Material Through Powder Metallurgy Route

NASA Astrophysics Data System (ADS)

Datta Banik, Bibhas; Dutta, Debasish; Ray, Siddhartha

2017-04-01

High speed steel tools can withstand high impact forces as they are tough in nature. But they cannot retain their hardness at elevated temperature i.e. their hot hardness is low. Therefore permissible cutting speed is low and tools wear out easily. Use of lubricants is essential for HSS cutting tools. On the other hand cemented carbide tools can withstand greater compressive force, but due to lower toughness the tool can break easily. Moreover the cost of the tool is comparatively high. To achieve a better machining economy, Fe-W-Co-Cr-C alloys are being used nowadays. Their toughness is as good as HSS tools and hardness is very near to carbide tools. Even, at moderate cutting speeds they can be safely used in old machines having vibration. Moreover it is much cheaper than carbide tools. This paper highlights the Manufacturing Technology of the alloy and studies the comparative tribological properties of the alloy and tungsten mono carbide.

Investigation of tool wear and surface roughness on machining of titanium alloy with MT-CVD cutting tool

NASA Astrophysics Data System (ADS)

Maity, Kalipada; Pradhan, Swastik

2018-04-01

In this study, machining of titanium alloy (grade 5) is carried out using MT-CVD coated cutting tool. Titanium alloys possess superior strength-to-weight ratio with good corrosion resistance. Most of the industries used titanium alloy for the manufacturing of various types of lightweight components. The parts made from Ti-6Al-4V largely used in aerospace, biomedical, automotive and marine sectors. The conventional machining of this material is very difficult, due to low thermal conductivity and high chemical reactivity properties. To achieve a good surface finish with minimum tool wear of cutting tool, the machining is carried out using MT-CVD coated cutting tool. The experiment is carried out using of Taguchi L27 array layout with three cutting variables and levels. To find out the optimum parametric setting desirability function analysis (DFA) approach is used. The analysis of variance is studied to know the percentage contribution of each cutting variables. The optimum parametric setting results calculated from DFA were validated through the confirmation test.

Identification of Technological Parameters of Ni-Alloys When Machining by Monolithic Ceramic Milling Tool

NASA Astrophysics Data System (ADS)

Czán, Andrej; Kubala, Ondrej; Danis, Igor; Czánová, Tatiana; Holubják, Jozef; Mikloš, Matej

2017-12-01

The ever-increasing production and the usage of hard-to-machine progressive materials are the main cause of continual finding of new ways and methods of machining. One of these ways is the ceramic milling tool, which combines the pros of conventional ceramic cutting materials and pros of conventional coating steel-based insert. These properties allow to improve cutting conditions and so increase the productivity with preserved quality known from conventional tools usage. In this paper, there is made the identification of properties and possibilities of this tool when machining of hard-to-machine materials such as nickel alloys using in airplanes engines. This article is focused on the analysis and evaluation ordinary technological parameters and surface quality, mainly roughness of surface and quality of machined surface and tool wearing.

Influence of non-edible vegetable based oil as cutting fluid on chip, surface roughness and cutting force during drilling operation of Mild Steel

NASA Astrophysics Data System (ADS)

Susmitha, M.; Sharan, P.; Jyothi, P. N.

2016-09-01

Friction between work piece-cutting tool-chip generates heat in the machining zone. The heat generated reduces the tool life, increases surface roughness and decreases the dimensional sensitiveness of work material. This can be overcome by using cutting fluids during machining. They are used to provide lubrication and cooling effects between cutting tool and work piece and cutting tool and chip during machining operation. As a result, important benefits would be achieved such longer tool life, easy chip flow and higher machining quality in the machining processes. Non-edible vegetable oils have received considerable research attention in the last decades owing to their remarkable improved tribological characteristics and due to increasing attention to environmental issues, have driven the lubricant industry toward eco friendly products from renewable sources. In the present work, different non-edible vegetable oils are used as cutting fluid during drilling of Mild steel work piece. Non-edible vegetable oils, used are Karanja oil (Honge), Neem oil and blend of these two oils. The effect of these cutting fluids on chip formation, surface roughness and cutting force are investigated and the results obtained are compared with results obtained with petroleum based cutting fluids and dry conditions.

Multilayer composition coatings for cutting tools: formation and performance properties

NASA Astrophysics Data System (ADS)

Tabakov, Vladimir P.; Vereschaka, Anatoly S.; Vereschaka, Alexey A.

2018-03-01

The paper considers the concept of a multi-layer architecture of the coating in which each layer has a predetermined functionality. Latest generation of coatings with multi-layered architecture for cutting tools secure a dual nature of the coating, in which coatings should not only improve the mechanical and physical characteristics of the cutting tool material, but also reduce the thermo-mechanical effect on the cutting tool determining wear intensity. Here are presented the results of the development of combined methods of forming multi-layer coatings with improved properties. Combined method of forming coatings using a pulsed laser allowed reducing excessively high levels of compressive residual stress and increasing micro hardness of the multilayered coatings. The results in testing coated HSS tools showed that the use of additional pulse of laser processing increases tool life up to 3 times. Using filtered cathodic vacuum arc deposition for the generation of multilayer coatings based on TiAlN compound has increased the wear-resistance of carbide tools by 2 fold compared with tool life of cutting tool with commercial TiN coatings. The aim of this study was to develop an innovative methodological approach to the deposition of multilayer coatings for cutting tools with functional architectural selection, properties and parameters of the coating based on sound knowledge of coating failure in machining process.

Impact of high-pressure coolant supply on chip formation in milling

NASA Astrophysics Data System (ADS)

Klocke, F.; Döbbeler, B.; Lakner, T.

2017-10-01

Machining of titanium alloys is considered as difficult, because of their high temperature strength, low thermal conductivity and low E-modulus, which contributes to high mechanical loads and high temperatures in the contact zone between tool and workpiece. The generated heat in the cutting zone can be dissipated only in a low extent. When cutting steel materials, up to 75% of the process heat is transported away by the chips, contrary to only 25% when machining titanium alloys. As a result, the cutting tool heats up, which leads to high tool wear. Therefore, machining of titanium alloys is only possible with relatively low cutting speeds. This leads to low levels of productivity for milling processes with titanium alloys. One way to increase productivity is to use more cutting edges in tools with the same diameter. However, the limiting factor of adding more cutting edges to a milling tool is the minimum size of the chip spaces, which are sufficient for a stable chip evacuation. This paper presents experimental results on the chip formation and chip size influenced by high-pressure coolant supply, which can lead to smaller chips and to smaller sizes of the chip spaces, respectively. Both influences, the pressure of the supplied coolant and the volumetric flow rate were individually examined. Alpha-beta annealed titanium TiAl6V4 was examined in relation to the reference material quenched and tempered steel 42CrMo4+QT (AISI 4140+QT). The work shows that with proper chip control due to high-pressure coolant supply in milling, the number of cutting edges on the same diameter tool can be increased, which leads to improved productivity.

Computer-aided analysis of cutting processes for brittle materials

NASA Astrophysics Data System (ADS)

Ogorodnikov, A. I.; Tikhonov, I. N.

2017-12-01

This paper is focused on 3D computer simulation of cutting processes for brittle materials and silicon wafers. Computer-aided analysis of wafer scribing and dicing is carried out with the use of the ANSYS CAE (computer-aided engineering) software, and a parametric model of the processes is created by means of the internal ANSYS APDL programming language. Different types of tool tip geometry are analyzed to obtain internal stresses, such as a four-sided pyramid with an included angle of 120° and a tool inclination angle to the normal axis of 15°. The quality of the workpieces after cutting is studied by optical microscopy to verify the FE (finite-element) model. The disruption of the material structure during scribing occurs near the scratch and propagates into the wafer or over its surface at a short range. The deformation area along the scratch looks like a ragged band, but the stress width is rather low. The theory of cutting brittle semiconductor and optical materials is developed on the basis of the advanced theory of metal turning. The fall of stress intensity along the normal on the way from the tip point to the scribe line can be predicted using the developed theory and with the verified FE model. The crystal quality and dimensions of defects are determined by the mechanics of scratching, which depends on the shape of the diamond tip, the scratching direction, the velocity of the cutting tool and applied force loads. The disunity is a rate-sensitive process, and it depends on the cutting thickness. The application of numerical techniques, such as FE analysis, to cutting problems enhances understanding and promotes the further development of existing machining technologies.

Exploring the influence of constitutive models and associated parameters for the orthogonal machining of Ti6Al4V

NASA Astrophysics Data System (ADS)

Pervaiz, S.; Anwar, S.; Kannan, S.; Almarfadi, A.

2018-04-01

Ti6Al4V is known as difficult-to-cut material due to its inherent properties such as high hot hardness, low thermal conductivity and high chemical reactivity. Though, Ti6Al4V is utilized by industrial sectors such as aeronautics, energy generation, petrochemical and bio-medical etc. For the metal cutting community, competent and cost-effective machining of Ti6Al4V is a challenging task. To optimize cost and machining performance for the machining of Ti6Al4V, finite element based cutting simulation can be a very useful tool. The aim of this paper is to develop a finite element machining model for the simulation of Ti6Al4V machining process. The study incorporates material constitutive models namely Power Law (PL) and Johnson – Cook (JC) material models to mimic the mechanical behaviour of Ti6Al4V. The study investigates cutting temperatures, cutting forces, stresses, and plastic strains with respect to different PL and JC material models with associated parameters. In addition, the numerical study also integrates different cutting tool rake angles in the machining simulations. The simulated results will be beneficial to draw conclusions for improving the overall machining performance of Ti6Al4V.

Analysis Of The Surface Roughness Obtained During The Dry Turning Of UNS A97050-T7 Aluminium Alloys

NASA Astrophysics Data System (ADS)

de Agustina, B.; Rubio, E. M.; Villeta, M.; Sebastián, M. A.

2009-11-01

Currently, in the aeronautical, aerospace and automotive industries there is high demand of materials such as the aluminium alloys that have high resistance even at high temperatures as well as a low density. For this reason, these alloys are widely used for the production of different elements that compose aircraft and aerospace vehicles. Nevertheless, in spite of the important role these materials have from the competitive point of view, they can commonly show problems of machinability associated with the tool wear. That has made that traditionally cutting fluids had been used in machining processes. However, they can contain environmentally harmful constituents and increase considerably the total cost of the process. Therefore, researches have been focused on the development of cleaner production technologies applications as dry machining. This leads to the search for combinations of cutting parameters and type of tools (types of coatings and different geometries) that could improve the machining under such conditions. The aim of this study is to analyse the relationship between the surface roughness obtained during the dry turning of aluminium UNS A97050-T7 bars and the cutting parameters (cutting speed and feed) using three different tools. As a first conclusion it could be affirmed that the feed was the cutting parameter more influential on the surface roughness and to a lesser extend the cutting speed, the type of tool and the interaction between the type of tool and the feed.

Ceramic tools insert assesment based on vickers indentation methodology

NASA Astrophysics Data System (ADS)

Husni; Rizal, Muhammad; Aziz M, M.; Wahyu, M.

2018-05-01

In the interrupted cutting process, the risk of tool chipping or fracture is higher than continues cutting. Therefore, the selection of suitable ceramic tools for interrupted cutting application become an important issue to assure that the cutting process is running effectively. At present, the performance of ceramics tools is assessed by conducting some cutting tests, which is required time and cost consuming. In this study, the performance of ceramic tools evaluated using hardness tester machine. The technique, in general, has a certain advantage compare with the more conventional methods; the experimental is straightforward involving minimal specimen preparation and the amount of material needed is small. Three types of ceramic tools AS10, CC650 and K090 have been used, each tool was polished then Vickers indentation test were performed with the load were 0.2, 0.5, 1, 2.5, 5 and 10 kgf. The results revealed that among the load used in the tests, the indentation loads of 5 kgf always produce well cracks as compared with others. Among the cutting tool used in the tests, AS10 has produced the shortest crack length and follow by CC 670, and K090. It is indicated that the shortest crack length of AS10 reflected that the tool has a highest dynamic load resistance among others insert.

Progress in development of coated indexable cemented carbide inserts for machining of iron based work piece materials

NASA Astrophysics Data System (ADS)

Czettl, C.; Pohler, M.

2016-03-01

Increasing demands on material properties of iron based work piece materials, e.g. for the turbine industry, complicate the machining process and reduce the lifetime of the cutting tools. Therefore, improved tool solutions, adapted to the requirements of the desired application have to be developed. Especially, the interplay of macro- and micro geometry, substrate material, coating and post treatment processes is crucial for the durability of modern high performance tool solutions. Improved and novel analytical methods allow a detailed understanding of material properties responsible for the wear behaviour of the tools. Those support the knowledge based development of tailored cutting materials for selected applications. One important factor for such a solution is the proper choice of coating material, which can be synthesized by physical or chemical vapor deposition techniques. Within this work an overview of state-of-the-art coated carbide grades is presented and application examples are shown to demonstrate their high efficiency. Machining processes for a material range from cast iron, low carbon steels to high alloyed steels are covered.

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075.

PubMed

Ghasemi, Amir Hossein; Khorasani, Amir Mahyar; Gibson, Ian

2018-01-16

Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5-8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

PubMed Central

Ghasemi, Amir Hossein; Khorasani, Amir Mahyar

2018-01-01

Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5–8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy. PMID:29337858

Study of PVD AlCrN Coating for Reducing Carbide Cutting Tool Deterioration in the Machining of Titanium Alloys.

PubMed

Cadena, Natalia L; Cue-Sampedro, Rodrigo; Siller, Héctor R; Arizmendi-Morquecho, Ana M; Rivera-Solorio, Carlos I; Di-Nardo, Santiago

2013-05-24

The manufacture of medical and aerospace components made of titanium alloys and other difficult-to-cut materials requires the parallel development of high performance cutting tools coated with materials capable of enhanced tribological and resistance properties. In this matter, a thin nanocomposite film made out of AlCrN (aluminum-chromium-nitride) was studied in this research, showing experimental work in the deposition process and its characterization. A heat-treated monolayer coating, competitive with other coatings in the machining of titanium alloys, was analyzed. Different analysis and characterizations were performed on the manufactured coating by scanning electron microscopy and energy-dispersive X-ray spectroscopy (SEM-EDXS), and X-ray diffraction (XRD). Furthermore, the mechanical behavior of the coating was evaluated through hardness test and tribology with pin-on-disk to quantify friction coefficient and wear rate. Finally, machinability tests using coated tungsten carbide cutting tools were executed in order to determine its performance through wear resistance, which is a key issue of cutting tools in high-end cutting at elevated temperatures. It was demonstrated that the specimen (with lower friction coefficient than previous research) is more efficient in machinability tests in Ti6Al4V alloys. Furthermore, the heat-treated monolayer coating presented better performance in comparison with a conventional monolayer of AlCrN coating.

Study of PVD AlCrN Coating for Reducing Carbide Cutting Tool Deterioration in the Machining of Titanium Alloys

PubMed Central

Cadena, Natalia L.; Cue-Sampedro, Rodrigo; Siller, Héctor R.; Arizmendi-Morquecho, Ana M.; Rivera-Solorio, Carlos I.; Di-Nardo, Santiago

2013-01-01

The manufacture of medical and aerospace components made of titanium alloys and other difficult-to-cut materials requires the parallel development of high performance cutting tools coated with materials capable of enhanced tribological and resistance properties. In this matter, a thin nanocomposite film made out of AlCrN (aluminum–chromium–nitride) was studied in this research, showing experimental work in the deposition process and its characterization. A heat-treated monolayer coating, competitive with other coatings in the machining of titanium alloys, was analyzed. Different analysis and characterizations were performed on the manufactured coating by scanning electron microscopy and energy-dispersive X-ray spectroscopy (SEM-EDXS), and X-ray diffraction (XRD). Furthermore, the mechanical behavior of the coating was evaluated through hardness test and tribology with pin-on-disk to quantify friction coefficient and wear rate. Finally, machinability tests using coated tungsten carbide cutting tools were executed in order to determine its performance through wear resistance, which is a key issue of cutting tools in high-end cutting at elevated temperatures. It was demonstrated that the specimen (with lower friction coefficient than previous research) is more efficient in machinability tests in Ti6Al4V alloys. Furthermore, the heat-treated monolayer coating presented better performance in comparison with a conventional monolayer of AlCrN coating. PMID:28809266

Investigation of the Effect of Tool Edge Geometry upon Cutting Variables, Tool Wear and Burr Formation Using Finite Element Simulation — A Progress Report

NASA Astrophysics Data System (ADS)

Sartkulvanich, Partchapol; Al-Zkeri, Ibrahim; Yen, Yung-Chang; Altan, Taylan

2004-06-01

This paper summarizes some of the progress made on FEM simulations of metal cutting processes conducted at the Engineering Research Center (ERC/NSM). Presented research focuses on the performance of various cutting edge geometries (hone and chamfer edges) for different tool materials and specifically on: 1) the effect of round and chamfer edge geometries on the cutting variables in machining carbon steels and 2) the effect of the edge hone size upon the flank wear and burr formation behavior in face milling of A356-T6 aluminum alloy. In the second task, an innovative design of edge preparation with varying hone size around the tool nose is also explored using FEM. In order to model three-dimensional conventional turning and face milling with two-dimensional orthogonal cutting simulations, 2D simulation cross-sections consisting of the cutting speed direction and chip flow direction are selected at different locations along the tool nose radius. Then the geometries of the hone and chamfer edges and their associated tool angles as well as uncut chip thickness are determined on these planes and employed in cutting simulations. The chip flow direction on the tool rake face are obtained by examining the wear grooves on the experimental inserts or estimated by using Oxley's approximation theory of oblique cutting. Simulation results are compared with the available experimental results (e.g. cutting forces) both qualitatively and quantitatively.

Tool wear mechanisms in turning titanium-aluminum-vanadium using tungsten carbide and polycrystalline diamond inserts

NASA Astrophysics Data System (ADS)

Schrock, David James

The objective of this work is to identify some of the tool wear mechanisms at the material level for the machining of titanium and to provide some understanding of these mechanisms for use in physics based tool wear models. Turning experiments were conducted at cutting speeds of 61m/min, 91m/min, and 122m/min on Ti-6Al-4V, an alloy of titanium, using two different grades of tungsten carbide cutting inserts and one grade of polycrystalline diamond inserts. Three-dimensional wear data and two-dimensional wear profiles of the rake face were generated using Confocal Laser Scanning Microscopy to quantify the tool wear mechanisms. Additionally, the microstructure of the deformed work material (chip) and un-deformed parent material (work piece) were studied using Orientation Imaging Microscopy (OIM). Observations from tool wear studies on the PCD inserts revealed the presence of two fundamentally different wear mechanisms operating at the different cutting speeds. Microstructural analyses of the chip and the work material showed phase dependent tool wear mechanisms for machining titanium. There is a high likelihood of phase change occurring in the work material during machining, with a transformation from the alpha phase to the beta phase. The observed dramatic increase in wear is attributed to a combination of increased diffusivity in the beta phase of the titanium alloy in conjunction with a higher degree of recrystallization of the prior beta phase upon cooling. Results of other observations such as the influence of carbide grain size on tool wear are also discussed.

Machines employing a hot gas jet to cut metals and nonmetallic materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Polyaev, V.M.; Aleksandrenkov, V.P.

1995-07-01

The flame-cutting of metals is a basic materials-processing operation performed in the course of machine-building and, in some sectors (shipbuilding, aircraft construction, petrochemicals) it is the most important operation. In addition, this method of cutting remains the main operation performed in the processing of scrap metal. The importance of it has occasioned the development of a wide range of cutting tools within just the last decade. Not surprisingly, VNIIavtogen-mash (the All-Union Scientific Research Institute of Machinery for the Gas Welding and Cutting of Metals) is the leading designer of metal-cutting tools in this country. The problem of efficiently cutting metalsmore » is gaining in importance and will continue to do so in coming years in connection with the conversion of military hardware to other uses, the decommissioning of old and obsolete equipment, and utilization of the enormous reserves of scrap in this country. There will thus be a significant increase in the amounts of existing high-alloy steels, nonferrous metals and their alloys, and composites that require cutting. A wide range of cutters is available for the gas-flame cutting of metals, Liquid fuels based on petroleum products are promising from the viewpoint of energy efficiency and performance. The operation of a new generation of cutters, referred to as thermo-gas jet cutters, is based on the principle of the destructive action of a hot, fast-moving, chemically active jet on the material to be cut.« less

Review on advanced composite materials boring mechanism and tools

NASA Astrophysics Data System (ADS)

Shi, Runping; Wang, Chengyong

2010-12-01

With the rapid development of aviation and aerospace manufacturing technology, advanced composite materials represented by carbon fibre reinforced plastics (CFRP) and super hybrid composites (fibre/metal plates) are more and more widely applied. The fibres are mainly carbon fibre, boron fibre, Aramid fiber and Sic fibre. The matrixes are resin matrix, metal matrix and ceramic matrix. Advanced composite materials have higher specific strength and higher specific modulus than glass fibre reinforced resin composites of the 1st generation. They are widely used in aviation and aerospace industry due to their high specific strength, high specific modulus, excellent ductility, anticorrosion, heat-insulation, sound-insulation, shock absorption and high&low temperature resistance. They are used for radomes, inlets, airfoils(fuel tank included), flap, aileron, vertical tail, horizontal tail, air brake, skin, baseboards and tails, etc. Its hardness is up to 62~65HRC. The holes are greatly affected by the fibre laminates direction of carbon fibre reinforced composite material due to its anisotropy when drilling in unidirectional laminates. There are burrs, splits at the exit because of stress concentration. Besides there is delamination and the hole is prone to be smaller. Burrs are caused by poor sharpness of cutting edge, delamination, tearing, splitting are caused by the great stress caused by high thrust force. Poorer sharpness of cutting edge leads to lower cutting performance and higher drilling force at the same time. The present research focuses on the interrelation between rotation speed, feed, drill's geometry, drill life, cutting mode, tools material etc. and thrust force. At the same time, holes quantity and holes making difficulty of composites have also increased. It requires high performance drills which won't bring out defects and have long tool life. It has become a trend to develop super hard material tools and tools with special geometry for drilling composite materials.

Review on advanced composite materials boring mechanism and tools

NASA Astrophysics Data System (ADS)

Shi, Runping; Wang, Chengyong

2011-05-01

With the rapid development of aviation and aerospace manufacturing technology, advanced composite materials represented by carbon fibre reinforced plastics (CFRP) and super hybrid composites (fibre/metal plates) are more and more widely applied. The fibres are mainly carbon fibre, boron fibre, Aramid fiber and Sic fibre. The matrixes are resin matrix, metal matrix and ceramic matrix. Advanced composite materials have higher specific strength and higher specific modulus than glass fibre reinforced resin composites of the 1st generation. They are widely used in aviation and aerospace industry due to their high specific strength, high specific modulus, excellent ductility, anticorrosion, heat-insulation, sound-insulation, shock absorption and high&low temperature resistance. They are used for radomes, inlets, airfoils(fuel tank included), flap, aileron, vertical tail, horizontal tail, air brake, skin, baseboards and tails, etc. Its hardness is up to 62~65HRC. The holes are greatly affected by the fibre laminates direction of carbon fibre reinforced composite material due to its anisotropy when drilling in unidirectional laminates. There are burrs, splits at the exit because of stress concentration. Besides there is delamination and the hole is prone to be smaller. Burrs are caused by poor sharpness of cutting edge, delamination, tearing, splitting are caused by the great stress caused by high thrust force. Poorer sharpness of cutting edge leads to lower cutting performance and higher drilling force at the same time. The present research focuses on the interrelation between rotation speed, feed, drill's geometry, drill life, cutting mode, tools material etc. and thrust force. At the same time, holes quantity and holes making difficulty of composites have also increased. It requires high performance drills which won't bring out defects and have long tool life. It has become a trend to develop super hard material tools and tools with special geometry for drilling composite materials.

Microwave interferometer controls cutting depth of plastics

NASA Technical Reports Server (NTRS)

Heisman, R. M.; Iceland, W. F.

1969-01-01

Microwave interferometer system controls the cutting of plastic materials to a prescribed depth. The interferometer is mounted on a carriage with a spindle and cutting tool. A cross slide, mounted on the carriage, allows the interferometer and cutter to move toward or away from the plastic workpiece.

AN EXPERIMENTAL STUDY OF CUTTING FLUID EFFECTS IN DRILLING. (R825370C057)

EPA Science Inventory

Experiments were designed and conducted on aluminum alloys and gray cast iron to determine the function of cutting fluid in drilling. The variables examined included speed, feed, hole depth, tool and workpiece material, cutting fluid condition, workpiece temperatures and drill...

Determination of high-strength materials diamond grinding rational modes

NASA Astrophysics Data System (ADS)

Arkhipov, P. V.; Lobanov, D. V.; Rychkov, D. A.; Yanyushkin, A. S.

2018-03-01

The analysis of methods of high-strength materials abrasive processing is carried out. This method made it possible to determine the necessary directions and prospects for the development of shaping combined methods. The need to use metal bonded diamond abrasive tools in combination with a different kind of energy is noted to improve the processing efficiency and reduce the complexity of operations. The complex of experimental research on revealing the importance of mechanical and electrical components of cutting regimes, on the cutting ability of diamond tools, as well as the need to reduce the specific consumption of an abrasive wheel as one of the important economic indicators of the processing process is performed. It is established that combined diamond grinding with simultaneous continuous correction of the abrasive wheel contributes to an increase in the cutting ability of metal bonded diamond abrasive tools when processing high-strength materials by an average of 30% compared to diamond grinding. Particular recommendations on the designation of technological factors are developed depending on specific production problems.

Modern laser technologies used for cutting textile materials

NASA Astrophysics Data System (ADS)

Isarie, Claudiu; Dragan, Anca; Isarie, Laura; Nastase, Dan

2006-02-01

With modern laser technologies we can cut multiple layers at once, yielding high production levels and short setup times between cutting runs. One example could be the operation of cutting the material named Nylon 66, used to manufacture automobile airbags. With laser, up to seven layers of Nylon 66 can be cut in one pass, that means high production rates on a single machine. Airbags must be precisely crafted piece of critical safety equipment that is built to very high levels of precision in a mass production environment. Of course, synthetic material, used for airbags, can be cut also by a conventional fixed blade system, but for a high production rates and a long term low-maintenance, laser cutting is most suitable. Most systems, are equipped with two material handling systems, which can cut on one half of he table while the finished product is being removed from the other half and the new stock material laid out. The laser system is reliable and adaptable to any flatbed-cutting task. Computer controlled industrial cutting and plotting machines are the latest offerings from a well established and experienced industrial engineering company that is dedicated to reduce cutting costs and boosting productivity in today's competitive industrial machine tool market. In this way, just one machine can carry out a multitude of production tasks. Authors have studied the cutting parameters for different textile materials, to reach the maximum output of the process.

Modeling and Tool Wear in Routing of CFRP

DOE Office of Scientific and Technical Information (OSTI.GOV)

Iliescu, D.; Fernandez, A.; Gutierrez-Orrantia, M. E.

2011-01-17

This paper presents the prediction and evaluation of feed force in routing of carbon composite material. In order to extend tool life and improve quality of the machined surface, a better understanding of uncoated and coated tool behaviors is required. This work describes (1) the optimization of the geometry of multiple teeth tools minimizing the tool wear and the feed force, (2) the optimization of tool coating and (3) the development of a phenomenological model between the feed force, the routing parameters and the tool wear. The experimental results indicate that the feed rate, the cutting speed and the toolmore » wear are the most significant factors affecting the feed force. In the case of multiple teeth tools, a particular geometry with 14 teeth right helix right cut and 11 teeth left helix right cut gives the best results. A thick AlTiN coating or a diamond coating can dramatically improve the tool life while minimizing the axial force, roughness and delamination. A wear model has then been developed based on an abrasive behavior of the tool. The model links the feed rate to the tool geometry parameters (tool diameter), to the process parameters (feed rate, cutting speed and depth of cut) and to the wear. The model presented has been verified by experimental tests.« less

Cutting of optical materials by using femtosecond laser pulses

NASA Astrophysics Data System (ADS)

Nolte, Stefan; Will, Matthias; Augustin, Markus; Triebel, Peter; Zoellner, Karsten; Tuennermann, Andreas

2001-11-01

In the past years, ultrashort pulse lasers have been established as precise and universal tools for the microstructuring of solid materials. Since thermal and mechanical influences are minimized, the application of this technology is also suitable for the structuring of optical materials and opens new possibilities. In this paper, the influence of pulse duration, pulse energy (fluence) and polarization on the cutting quality for glass and silicon will be discussed. As a concrete application, the cutting and micromarking of dielectric coated mirrors for high power fiber lasers will be highlighted.

Distribution of contact loads over the flank-land of the cutter with a rounded cutting edge

NASA Astrophysics Data System (ADS)

Kozlov, V.; Gerasimov, A.; Kim, A.

2016-04-01

In this paper, contact conditions between a tool and a workpiece material for wear-simulating turning by a cutter with a sharp-cornered edge and with a rounded cutting edge are analysed. The results of the experimental study of specific contact load distribution over the artificial flank wear-land of the cutter in free orthogonal turning of the disk from titanium alloy (Ti6Al2Mo2Cr), ductile (63Cu) and brittle (57Cu1Al3Mn) brasses are described. Investigations were carried out by the method of ‘split cutter’ and by the method of the artificial flank-land of variable width. The experiments with a variable feed rate and a cutting speed show that in titanium alloy machining with a sharp-cornered cutting edge the highest normal contact load (σh max = 3400…2200 MPa) is observed immediately at the cutting edge, and the curve has a horizontal region with the length of 0.2… 0.6 mm. At a distance from the cutting edge, the value of specific normal contact load is dramatically reduced to 1100…500 MPa. The character of normal contact load for a rounded cutting edge is different -it is uniform, and its value is approximately 2 times smaller compared to machining with a sharp-cornered cutting edge. In author’s opinion it is connected with generation of a seizure zone in a chip formation region and explains the capacity of highly worn-out cutting tools for titanium alloys machining. The paper analyses the distribution of tangential contact loads over the flank land, which pattern differs considerably for machining with a sharp-cornered edge and with a rounded cutting edge. Abbreviation and symbols: m/s - meter per second (cutting speed v); mm/r - millimeter per revolution (feed rate f); MPa - mega Pascal (specific contact load as a stress σ or τ) hf - the width of the flank wear land (chamfer) of the cutting tool, flank wear land can be natural or artificial like the one in this paper [mm]; xh - distance from the cutting edge on the surface of the flank-land [mm]; σh - normal specific contact load on the flank land [MPa]; τh - tangential (shear) specific contact load on the flank land [MPa]; HSS - high speed steel (material of cutting tool); Py - radial component of cutting force [N]; Py r - radial component of cutting force on the rake face [N]; Pz - tangential component of cutting force [N]; γ - rake angle of the cutting tool [°] α - clearance angle of the sharp cutting tool [°] αh - clearance angle of the flank wear land [°] ρ - rounding off radius of the cutting edge [mm]; b - width of the machined disk [mm].

3D FEM Simulation of Flank Wear in Turning

NASA Astrophysics Data System (ADS)

Attanasio, Aldo; Ceretti, Elisabetta; Giardini, Claudio

2011-05-01

This work deals with tool wear simulation. Studying the influence of tool wear on tool life, tool substitution policy and influence on final part quality, surface integrity, cutting forces and power consumption it is important to reduce the global process costs. Adhesion, abrasion, erosion, diffusion, corrosion and fracture are some of the phenomena responsible of the tool wear depending on the selected cutting parameters: cutting velocity, feed rate, depth of cut, …. In some cases these wear mechanisms are described by analytical models as a function of process variables (temperature, pressure and sliding velocity along the cutting surface). These analytical models are suitable to be implemented in FEM codes and they can be utilized to simulate the tool wear. In the present paper a commercial 3D FEM software has been customized to simulate the tool wear during turning operations when cutting AISI 1045 carbon steel with uncoated tungsten carbide tip. The FEM software was improved by means of a suitable subroutine able to modify the tool geometry on the basis of the estimated tool wear as the simulation goes on. Since for the considered couple of tool-workpiece material the main phenomena generating wear are the abrasive and the diffusive ones, the tool wear model implemented into the subroutine was obtained as combination between the Usui's and the Takeyama and Murata's models. A comparison between experimental and simulated flank tool wear curves is reported demonstrating that it is possible to simulate the tool wear development.

Study of the performances of nano-case treatment cutting tools on carbon steel work material during turning operation

NASA Astrophysics Data System (ADS)

Afolalu, S. A.; Okokpujie, I. P.; Salawu, E. Y.; Abioye, A. A.; Abioye, O. P.; Ikumapayi, O. M.

2018-04-01

The degree of holding temperature and time play a major role in nano-case treatment of cutting tools which immensely contributed to its performance during machining operation. The objective of this research work is to carryout comparative study of performance of nano-case treatment tools developed using low and medium carbon steel as work piece. Turning operation was carried out under two different categories with specific work piece on universal lathe machine using HSS cutting tools 100 mm × 12mm × 12mm that has been nano-case treated under varying conditions of temperatures and timeof 800,850, 900, 950°C and 60, 90, 120 mins respectively. The turning parameters used in evaluating this experiment were cutting speed of 270, 380 and 560mm/min, feed rate of 0.15, 0.20 and 0.25 mm/min, depth of cut of 2mm, work piece diameter of 25mm and rake angle of 7° each at three levels. The results of comparative study of their performances revealed that the timespent in the machining of low carbon steel material at a minimum temperature and time of 800°C, 60 mins were1.50, 2.17 mins while at maximum temperature and time of 950°C, 120 mins were 1.19, 2.02 mins. It was also observed that at a corresponding constant speed of 270,380 and 560mm/min at higher temperature and time, a relative increased in the length of cut were observed. Critical observation of the result showed that at higher case hardening temperature and time (950°C/120mins), the HSS cutting tool gave a better performance as lesser time was consumed during the turning operation.

Pre-Finishing of SiC for Optical Applications

NASA Technical Reports Server (NTRS)

Rozzi, Jay; Clavier, Odile; Gagne, John

2011-01-01

13 Manufacturing & Prototyping A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process. DRM is a deterministic machining process associated with conditions under high hydrostatic pressures and very small depths of cut. Under such conditions, using high negative-rake angle cutting tools, the high-pressure region near the tool corresponds to a plastic zone, where even a brittle material will behave in a ductile manner. In the high-MRR processing step, the objective is to remove material with a sufficiently high rate such that the process is economical, without inducing large-scale subsurface damage. A laser-assisted machining approach was evaluated whereby a CO2 laser was focused in advance of the cutting tool. While CVD (chemical vapor deposition) SiC was successfully machined with this approach, the cutting forces were substantially higher than cuts at room temperature under the same machining conditions. During the experiments, the expansion of the part and the tool due to the heating was carefully accounted for. The higher cutting forces are most likely due to a small reduction in the shear strength of the material compared with a larger increase in friction forces due to the thermal softening effect. The key advantage is that the hybrid machine approach has the potential to achieve optical quality without the need for a separate optical finishing step. Also, this method is scalable, so one can easily progress from machining 50-mm-diameter samples to the 250-mm-diameter mirror that NASA desires.

A Performance Comparison Study of Uncoated and TiAlN Coated Carbide End Mill on Machining of the Al-35Zn Alloy

NASA Astrophysics Data System (ADS)

Bayraktar, S.; Hekimoglu, A. P.; Turgut, Y.; Haciosmanoglu, M.

2018-01-01

In this study, Al-35Zn alloy was produced by permanent mold casting. To investigate the cutting performance of uncoated and TiAlN coated carbide end mills on this alloy, a series of tests were carried out in the CNC vertical machining center at a constant cutting speed, feed rate and depth of cut. The results obtained from the tests showed that uncoated carbide end mill have lower cutting force and surface roughness than TiAlN coated carbide end mill. These observations are discussed in terms of the alloys properties, cutting tool surfaces, and friction and wear behavior between the cutting tool and the material.

Synthesis and Characterization of Low-Cost Superhard Transition-Metal Borides

NASA Astrophysics Data System (ADS)

Kaner, Richard

2013-06-01

The increasing demand for high-performance cutting and forming tools, along with the shortcomings of traditional tool materials such as diamond (unable to cut ferrous materials), cubic boron nitride (expensive) and tungsten carbide (relatively-low hardness), has motivated the search for new superhard materials for these applications. This has led us to a new class of superhard materials, dense refractory transition-metal borides, which promise to address some of the existing problems of conventional superhard materials. For example, we have synthesized rhenium diboride (ReB2) using arc melting at ambient pressure. This superhard material has demonstrated an excellent electrical conductivity and superior mechanical properties, including a Vickers hardness of 48.0 GPa (under an applied load of 0.49 N). To further increase the hardness and lower the materials costs, we have begun exploring high boron content metal borides including tungsten tetraboride (WB4) . We have synthesized WB4 by arc melting and studied its hardness and high-pressure behavior. With a similar Vickers hardness (43.3 GPa under a load of 0.49 N) and bulk modulus (326-339 GPa) to ReB2, WB4 offers a lower cost alternative and has the potential to be used in cutting tools. To further enhance the hardness of this superhard metal, we have created the binary and ternary solid solutions of WB4 with Cr, Mn and Ta, the results of which show a hardness increase of up to 20 percent. As with other metals, these metallic borides can be readily cut and shaped using electric discharge machining (EDM).

Experimental evaluation of tool wear throughout a continuous stroke blanking process of quenched 22MnB5 ultra-high-strength steel

NASA Astrophysics Data System (ADS)

Vogt, S.; Neumayer, F. F.; Serkyov, I.; Jesner, G.; Kelsch, R.; Geile, M.; Sommer, A.; Golle, R.; Volk, W.

2017-09-01

Steel is the most common material used in vehicles’ chassis, which makes its research an important topic for the automotive industry. Recently developed ultra-high-strength steels (UHSS) provide extreme tensile strength up to 1,500 MPa and combine great crashworthiness with good weight reduction potential. However, in order to reach the final shape of sheet metal parts additional cutting steps such as trimming and piercing are often required. The final trimming of quenched metal sheets presents a huge challenge to a conventional process, mainly because of the required extreme cutting force. The high cutting impact, due to the materials’ brittleness, causes excessive tool wear or even sudden tool failure. Therefore, a laser is commonly used for the cutting process, which is time and energy consuming. The purpose of this paper is to demonstrate the capability of a conventional blanking tool design in a continuous stroke piercing process using boron steel 22MnB5 sheets. Two different types of tool steel were tested for their suitability as active cutting elements: electro-slag remelted (ESR) cold work tool steel Bohler K340 ISODUR and powder-metallurgic (PM) high speed steel Bohler S390 MICROCLEAN. A FEM study provided information about an optimized punch design, which withstands buckling under high cutting forces. The wear behaviour of the process was assessed by the tool wear of the active cutting elements as well as the quality of cut surfaces.

An experimental investigation of pulsed laser-assisted machining of AISI 52100 steel

NASA Astrophysics Data System (ADS)

Panjehpour, Afshin; Soleymani Yazdi, Mohammad R.; Shoja-Razavi, Reza

2014-11-01

Grinding and hard turning are widely used for machining of hardened bearing steel parts. Laser-assisted machining (LAM) has emerged as an efficient alternative to grinding and hard turning for hardened steel parts. In most cases, continuous-wave lasers were used as a heat source to cause localized heating prior to material removal by a cutting tool. In this study, an experimental investigation of pulsed laser-assisted machining of AISI 52100 bearing steel was conducted. The effects of process parameters (i.e., laser mean power, pulse frequency, pulse energy, cutting speed and feed rate) on state variables (i.e., material removal temperature, specific cutting energy, surface roughness, microstructure, tool wear and chip formation) were investigated. At laser mean power of 425 W with frequency of 120 Hz and cutting speed of 70 m/min, the benefit of LAM was shown by 25% decrease in specific cutting energy and 18% improvement in surface roughness, as compared to those of the conventional machining. It was shown that at constant laser power, the increase of laser pulse energy causes the rapid increase in tool wear rate. Pulsed laser allowed efficient control of surface temperature and heat penetration in material removal region. Examination of the machined subsurface microstructure and microhardness profiles showed no change under LAM and conventional machining. Continuous chips with more uniform plastic deformation were produced in LAM.

Analyzing the effect of cutting parameters on surface roughness and tool wear when machining nickel based hastelloy - 276

NASA Astrophysics Data System (ADS)

Khidhir, Basim A.; Mohamed, Bashir

2011-02-01

Machining parameters has an important factor on tool wear and surface finish, for that the manufacturers need to obtain optimal operating parameters with a minimum set of experiments as well as minimizing the simulations in order to reduce machining set up costs. The cutting speed is one of the most important cutting parameter to evaluate, it clearly most influences on one hand, tool life, tool stability, and cutting process quality, and on the other hand controls production flow. Due to more demanding manufacturing systems, the requirements for reliable technological information have increased. For a reliable analysis in cutting, the cutting zone (tip insert-workpiece-chip system) as the mechanics of cutting in this area are very complicated, the chip is formed in the shear plane (entrance the shear zone) and is shape in the sliding plane. The temperature contributed in the primary shear, chamfer and sticking, sliding zones are expressed as a function of unknown shear angle on the rake face and temperature modified flow stress in each zone. The experiments were carried out on a CNC lathe and surface finish and tool tip wear are measured in process. Machining experiments are conducted. Reasonable agreement is observed under turning with high depth of cut. Results of this research help to guide the design of new cutting tool materials and the studies on evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy - 276 machining.

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part.

PubMed

Ahmed, Yassmin Seid; Fox-Rabinovich, German; Paiva, Jose Mario; Wagg, Terry; Veldhuis, Stephen Clarence

2017-10-25

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool-chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear.

Friction stir welding tool and process for welding dissimilar materials

DOEpatents

Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

2013-05-07

A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

Cold machining of high density tungsten and other materials

NASA Technical Reports Server (NTRS)

Ziegelmeier, P.

1969-01-01

Cold machining process, which uses a sub-zero refrigerated cutting fluid, is used for machining refractory or reactive metals and alloys. Special carbide tools for turning and drilling these alloys further improve the cutting performance.

Determination of Optimum Cutting Parameters for Surface Roughness in Turning AL-B4C Composites

NASA Astrophysics Data System (ADS)

Channabasavaraja, H. K.; Nagaraj, P. M.; Srinivasan, D.

2016-09-01

Many materials such as alloys, composites find their applications on the basis of machinability, cost and availability. In the present work, machinability of Aluminium 1100 and Boron carbide (AL+ B4C) composite material is examined by using lathe tool dynometers (BANKA Lathe) by varying the cutting parameters like spindle speed, Depth of cut and Feed rate in 3 levels. Also, surface roughness is measured against the weight % of reinforcement in the composite (0, 4 and 8 %). From the study it is observed that the hardness of a composite material increases with increase in weight % of reinforcement material (B4C) by 26.27 and 66.7 % respectively. The addition of reinforcement materials influences the machinability. The cutting force in both X and Z direction were also found increment with the reinforcement percentage.

Cutting Zone Temperature Identification During Machining of Nickel Alloy Inconel 718

NASA Astrophysics Data System (ADS)

Czán, Andrej; Daniš, Igor; Holubják, Jozef; Zaušková, Lucia; Czánová, Tatiana; Mikloš, Matej; Martikáň, Pavol

2017-12-01

Quality of machined surface is affected by quality of cutting process. There are many parameters, which influence on the quality of the cutting process. The cutting temperature is one of most important parameters that influence the tool life and the quality of machined surfaces. Its identification and determination is key objective in specialized machining processes such as dry machining of hard-to-machine materials. It is well known that maximum temperature is obtained in the tool rake face at the vicinity of the cutting edge. A moderate level of cutting edge temperature and a low thermal shock reduce the tool wear phenomena, and a low temperature gradient in the machined sublayer reduces the risk of high tensile residual stresses. The thermocouple method was used to measure the temperature directly in the cutting zone. An original thermocouple was specially developed for measuring of temperature in the cutting zone, surface and subsurface layers of machined surface. This paper deals with identification of temperature and temperature gradient during dry peripheral milling of Inconel 718. The measurements were used to identification the temperature gradients and to reconstruct the thermal distribution in cutting zone with various cutting conditions.

Effect of Cutting Tool Properties and Depth of Cut in Rock Cutting: An Experimental Study

NASA Astrophysics Data System (ADS)

Rostamsowlat, Iman

2018-06-01

The current paper is designed to investigate the effect of worn (blunt) polycrystalline diamond compact cutter properties on both the contact stress (σ) and friction coefficient ( μ) mobilized at the wear flat-rock interface at different inclination angles of the wear flat surface and at a wide range of depths of cut. An extensive and comprehensive set of cutting experiments is carried out on two sedimentary rocks (one limestone and one sandstone) using a state-of-the-art rock cutting equipment (Wombat) and various blunt cutters. Experiments with blunt cutters are characterized by different wear flat inclination angles (β), different wear flat surface roughness (Ra), different wear flat material, and different cutting tool velocities ({\\varvec{v}}) were conducted. The experimental results show that both the contact stress and friction coefficient are predominantly affected by the wear flat roughness at all inclination angles of the wear flat; however, the cutting tool velocity has a negligible influence on both the contact stress and friction coefficient. Further investigations suggest that the contact stress is greatly affected by the depth of cut within the plastic regime of frictional contact while the contact stress is insensitive to the depth of cut within the elastic regime.

Recent developments in turning hardened steels - A review

NASA Astrophysics Data System (ADS)

Sivaraman, V.; Prakash, S.

2017-05-01

Hard materials ranging from HRC 45 - 68 such as hardened AISI H13, AISI 4340, AISI 52100, D2 STL, D3 STEEL Steel etc., need super hard tool materials to machine. Turning of these hard materials is termed as hard turning. Hard turning makes possible direct machining of the hard materials and also eliminates the lubricant requirement and thus favoring dry machining. Hard turning is a finish turning process and hence conventional grinding is not required. Development of the new advanced super hard tool materials such as ceramic inserts, Cubic Boron Nitride, Polycrystalline Cubic Boron Nitride etc. enabled the turning of these materials. PVD and CVD methods of coating have made easier the production of single and multi layered coated tool inserts. Coatings of TiN, TiAlN, TiC, Al2O3, AlCrN over cemented carbide inserts has lead to the machining of difficult to machine materials. Advancement in the process of hard machining paved way for better surface finish, long tool life, reduced tool wear, cutting force and cutting temperatures. Micro and Nano coated carbide inserts, nanocomposite coated PCBN inserts, micro and nano CBN coated carbide inserts and similar developments have made machining of hardened steels much easier and economical. In this paper, broad literature review on turning of hardened steels including optimizing process parameters, cooling requirements, different tool materials etc., are done.

Erosion-resistant composite material

DOEpatents

Finch, C.B.; Tennery, V.J.; Curlee, R.M.

A highly erosion-resistant composite material is formed of chemical vapor-deposited titanium diboride on a sintered titanium diboride-nickel substrate. This material may be suitable for use in cutting tools, coal liquefaction systems, etc.

High performance cutting of aircraft and turbine components

NASA Astrophysics Data System (ADS)

Krämer, A.; Lung, D.; Klocke, F.

2012-04-01

Titanium and nickel-based alloys belong to the group of difficult-to-cut materials. The machining of these high-temperature alloys is characterized by low productivity and low process stability as a result of their physical and mechanical properties. Major problems during the machining of these materials are low applicable cutting speeds due to excessive tool wear, long machining times, and thus high manufacturing costs, as well as the formation of ribbon and snarled chips. Under these conditions automation of the production process is limited. This paper deals with strategies to improve machinability of titanium and nickel-based alloys. Using the example of the nickel-based alloy Inconel 718 high performance cutting with advanced cutting materials, such as PCBN and cutting ceramics, is presented. Afterwards the influence of different cooling strategies, like high-pressure lubricoolant supply and cryogenic cooling, during machining of TiAl6V4 is shown.

Effects of cutting parameters and machining environments on surface roughness in hard turning using design of experiment

NASA Astrophysics Data System (ADS)

Mia, Mozammel; Bashir, Mahmood Al; Dhar, Nikhil Ranjan

2016-07-01

Hard turning is gradually replacing the time consuming conventional turning process, which is typically followed by grinding, by producing surface quality compatible to grinding. The hard turned surface roughness depends on the cutting parameters, machining environments and tool insert configurations. In this article the variation of the surface roughness of the produced surfaces with the changes in tool insert configuration, use of coolant and different cutting parameters (cutting speed, feed rate) has been investigated. This investigation was performed in machining AISI 1060 steel, hardened to 56 HRC by heat treatment, using coated carbide inserts under two different machining environments. The depth of cut, fluid pressure and material hardness were kept constant. The Design of Experiment (DOE) was performed to determine the number and combination sets of different cutting parameters. A full factorial analysis has been performed to examine the effect of main factors as well as interaction effect of factors on surface roughness. A statistical analysis of variance (ANOVA) was employed to determine the combined effect of cutting parameters, environment and tool configuration. The result of this analysis reveals that environment has the most significant impact on surface roughness followed by feed rate and tool configuration respectively.

Laser cutting of various materials: Kerf width size analysis and life cycle assessment of cutting process

NASA Astrophysics Data System (ADS)

Yilbas, Bekir Sami; Shaukat, Mian Mobeen; Ashraf, Farhan

2017-08-01

Laser cutting of various materials including Ti-6Al-4V alloy, steel 304, Inconel 625, and alumina is carried out to assess the kerf width size variation along the cut section. The life cycle assessment is carried out to determine the environmental impact of the laser cutting in terms of the material waste during the cutting process. The kerf width size is formulated and predicted using the lump parameter analysis and it is measured from the experiments. The influence of laser output power and laser cutting speed on the kerf width size variation is analyzed using the analytical tools including scanning electron and optical microscopes. In the experiments, high pressure nitrogen assisting gas is used to prevent oxidation reactions in the cutting section. It is found that the kerf width size predicted from the lump parameter analysis agrees well with the experimental data. The kerf width size variation increases with increasing laser output power. However, this behavior reverses with increasing laser cutting speed. The life cycle assessment reveals that material selection for laser cutting is critical for the environmental protection point of view. Inconel 625 contributes the most to the environmental damages; however, recycling of the waste of the laser cutting reduces this contribution.

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

PubMed Central

Fox-Rabinovich, German; Wagg, Terry

2017-01-01

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool–chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear. PMID:29068405

Machinability of titanium metal matrix composites (Ti-MMCs)

NASA Astrophysics Data System (ADS)

Aramesh, Maryam

Titanium metal matrix composites (Ti-MMCs), as a new generation of materials, have various potential applications in aerospace and automotive industries. The presence of ceramic particles enhances the physical and mechanical properties of the alloy matrix. However, the hard and abrasive nature of these particles causes various issues in the field of their machinability. Severe tool wear and short tool life are the most important drawbacks of machining this class of materials. There is very limited work in the literature regarding the machinability of this class of materials especially in the area of tool life estimation and tool wear. By far, polycrystalline diamond (PCD) tools appear to be the best choice for machining MMCs from researchers' point of view. However, due to their high cost, economical alternatives are sought. Cubic boron nitride (CBN) inserts, as the second hardest available tools, show superior characteristics such as great wear resistance, high hardness at elevated temperatures, a low coefficient of friction and a high melting point. Yet, so far CBN tools have not been studied during machining of Ti-MMCs. In this study, a comprehensive study has been performed to explore the tool wear mechanisms of CBN inserts during turning of Ti-MMCs. The unique morphology of the worn faces of the tools was investigated for the first time, which led to new insights in the identification of chemical wear mechanisms during machining of Ti-MMCs. Utilizing the full tool life capacity of cutting tools is also very crucial, due to the considerable costs associated with suboptimal replacement of tools. This strongly motivates development of a reliable model for tool life estimation under any cutting conditions. In this study, a novel model based on the survival analysis methodology is developed to estimate the progressive states of tool wear under any cutting conditions during machining of Ti-MMCs. This statistical model takes into account the machining time in addition to the effect of cutting parameters. Thus, promising results were obtained which showed a very good agreement with the experimental results. Moreover, a more advanced model was constructed, by adding the tool wear as another variable to the previous model. Therefore, a new model was proposed for estimating the remaining life of worn inserts under different cutting conditions, using the current tool wear data as an input. The results of this model were validated with the experimental results. The estimated results were well consistent with the results obtained from the experiments.

Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V.

PubMed

Patil, Sandip; Joshi, Shashikant; Tewari, Asim; Joshi, Suhas S

2014-02-01

The titanium alloys cause high machining heat generation and consequent rapid wear of cutting tool edges during machining. The ultrasonic assisted turning (UAT) has been found to be very effective in machining of various materials; especially in the machining of "difficult-to-cut" material like Ti6Al4V. The present work is a comprehensive study involving 2D FE transient simulation of UAT in DEFORM framework and their experimental characterization. The simulation shows that UAT reduces the stress level on cutting tool during machining as compared to that of in continuous turning (CT) barring the penetration stage, wherein both tools are subjected to identical stress levels. There is a 40-45% reduction in cutting forces and about 48% reduction in cutting temperature in UAT over that of in CT. However, the reduction magnitude reduces with an increase in the cutting speed. The experimental analysis of UAT process shows that the surface roughness in UAT is lower than in CT, and the UATed surfaces have matte finish as against the glossy finish on the CTed surfaces. Microstructural observations of the chips and machined surfaces in both processes reveal that the intensity of thermal softening and shear band formation is reduced in UAT over that of in CT. Copyright © 2013 Elsevier B.V. All rights reserved.

Experimental investigation and modelling of surface roughness and resultant cutting force in hard turning of AISI H13 Steel

NASA Astrophysics Data System (ADS)

Boy, M.; Yaşar, N.; Çiftçi, İ.

2016-11-01

In recent years, turning of hardened steels has replaced grinding for finishing operations. This process is compared to grinding operations; hard turning has higher material removal rates, the possibility of greater process flexibility, lower equipment costs, and shorter setup time. CBN or ceramic cutting tools are widely used hard part machining. For successful application of hard turning, selection of suitable cutting parameters for a given cutting tool is an important step. For this purpose, an experimental investigation was conducted to determine the effects of cutting tool edge geometry, feed rate and cutting speed on surface roughness and resultant cutting force in hard turning of AISI H13 steel with ceramic cutting tools. Machining experiments were conducted in a CNC lathe based on Taguchi experimental design (L16) in different levels of cutting parameters. In the experiments, a Kistler 9257 B, three cutting force components (Fc, Ff and Fr) piezoelectric dynamometer was used to measure cutting forces. Surface roughness measurements were performed by using a Mahrsurf PS1 device. For statistical analysis, analysis of variance has been performed and mathematical model have been developed for surface roughness and resultant cutting forces. The analysis of variance results showed that the cutting edge geometry, cutting speed and feed rate were the most significant factors on resultant cutting force while the cutting edge geometry and feed rate were the most significant factor for the surface roughness. The regression analysis was applied to predict the outcomes of the experiment. The predicted values and measured values were very close to each other. Afterwards a confirmation tests were performed to make a comparison between the predicted results and the measured results. According to the confirmation test results, measured values are within the 95% confidence interval.

Thermal-mechanical modeling of laser ablation hybrid machining

NASA Astrophysics Data System (ADS)

Matin, Mohammad Kaiser

2001-08-01

Hard, brittle and wear-resistant materials like ceramics pose a problem when being machined using conventional machining processes. Machining ceramics even with a diamond cutting tool is very difficult and costly. Near net-shape processes, like laser evaporation, produce micro-cracks that require extra finishing. Thus it is anticipated that ceramic machining will have to continue to be explored with new-sprung techniques before ceramic materials become commonplace. This numerical investigation results from the numerical simulations of the thermal and mechanical modeling of simultaneous material removal from hard-to-machine materials using both laser ablation and conventional tool cutting utilizing the finite element method. The model is formulated using a two dimensional, planar, computational domain. The process simulation acronymed, LAHM (Laser Ablation Hybrid Machining), uses laser energy for two purposes. The first purpose is to remove the material by ablation. The second purpose is to heat the unremoved material that lies below the ablated material in order to ``soften'' it. The softened material is then simultaneously removed by conventional machining processes. The complete solution determines the temperature distribution and stress contours within the material and tracks the moving boundary that occurs due to material ablation. The temperature distribution is used to determine the distance below the phase change surface where sufficient ``softening'' has occurred, so that a cutting tool may be used to remove additional material. The model incorporated for tracking the ablative surface does not assume an isothermal melt phase (e.g. Stefan problem) for laser ablation. Both surface absorption and volume absorption of laser energy as function of depth have been considered in the models. LAHM, from the thermal and mechanical point of view is a complex machining process involving large deformations at high strain rates, thermal effects of the laser, removal of materials and contact between workpiece and tool. The theoretical formulation associated with LAHM for solving the thermal-mechanical problem using the finite element method is presented. The thermal formulation is incorporated in the user defined subroutines called by ABAQUS/Standard. The mechanical portion is modeled using ABAQUS/Explicit's general capabilities of modeling interactions involving contact and separation. The results obtained from the FEA simulations showed that the cutting force decrease considerably in both LAEM Surface Absorption (LARM-SA) and LAHM volume absorption (LAHM-VA) models relative to LAM model. It was observed that the HAZ can be expanded or narrowed depending on the laser speed and power. The cutting force is minimal at the last extent of the HAZ. In both the models the laser ablates material thus reducing material stiffness as well as relaxing the thermal stress. The stress values obtained showed compressive yield stress just below the ablated surface and chip. The failure occurs by conventional cutting where tensile stress exceeds the tensile strength of the material at that temperature. In this hybrid machining process the advantages of both the individual machining processes were realized.

The study on force, surface integrity, tool life and chip on laser assisted machining of inconel 718 using Nd:YAG laser source.

PubMed

Venkatesan, K

2017-07-01

Inconel 718, a high-temperature alloy, is a promising material for high-performance aerospace gas turbine engines components. However, the machining of the alloy is difficult owing to immense shear strength, rapid work hardening rate during turning, and less thermal conductivity. Hence, like ceramics and composites, the machining of this alloy is considered as difficult-to-turn materials. Laser assisted turning method has become a promising solution in recent years to lessen cutting stress when materials that are considered difficult-to-turn, such as Inconel 718 is employed. This study investigated the influence of input variables of laser assisted machining on the machinability aspect of the Inconel 718. The comparison of machining characteristics has been carried out to analyze the process benefits with the variation of laser machining variables. The laser assisted machining variables are cutting speeds of 60-150 m/min, feed rates of 0.05-0.125 mm/rev with a laser power between 1200 W and 1300 W. The various output characteristics such as force, roughness, tool life and geometrical characteristic of chip are investigated and compared with conventional machining without application of laser power. From experimental results, at a laser power of 1200 W, laser assisted turning outperforms conventional machining by 2.10 times lessening in cutting force, 46% reduction in surface roughness as well as 66% improvement in tool life when compared that of conventional machining. Compared to conventional machining, with the application of laser, the cutting speed of carbide tool has increased to a cutting condition of 150 m/min, 0.125 mm/rev. Microstructural analysis shows that no damage of the subsurface of the workpiece.

Optimization of Milling Parameters Employing Desirability Functions

NASA Astrophysics Data System (ADS)

Ribeiro, J. L. S.; Rubio, J. C. Campos; Abrão, A. M.

2011-01-01

The principal aim of this paper is to investigate the influence of tool material (one cermet and two coated carbide grades), cutting speed and feed rate on the machinability of hardened AISI H13 hot work steel, in order to identify the cutting conditions which lead to optimal performance. A multiple response optimization procedure based on tool life, surface roughness, milling forces and the machining time (required to produce a sample cavity) was employed. The results indicated that the TiCN-TiN coated carbide and cermet presented similar results concerning the global optimum values for cutting speed and feed rate per tooth, outperforming the TiN-TiCN-Al2O3 coated carbide tool.

Hybrid ABC Optimized MARS-Based Modeling of the Milling Tool Wear from Milling Run Experimental Data

PubMed Central

García Nieto, Paulino José; García-Gonzalo, Esperanza; Ordóñez Galán, Celestino; Bernardo Sánchez, Antonio

2016-01-01

Milling cutters are important cutting tools used in milling machines to perform milling operations, which are prone to wear and subsequent failure. In this paper, a practical new hybrid model to predict the milling tool wear in a regular cut, as well as entry cut and exit cut, of a milling tool is proposed. The model was based on the optimization tool termed artificial bee colony (ABC) in combination with multivariate adaptive regression splines (MARS) technique. This optimization mechanism involved the parameter setting in the MARS training procedure, which significantly influences the regression accuracy. Therefore, an ABC–MARS-based model was successfully used here to predict the milling tool flank wear (output variable) as a function of the following input variables: the time duration of experiment, depth of cut, feed, type of material, etc. Regression with optimal hyperparameters was performed and a determination coefficient of 0.94 was obtained. The ABC–MARS-based model's goodness of fit to experimental data confirmed the good performance of this model. This new model also allowed us to ascertain the most influential parameters on the milling tool flank wear with a view to proposing milling machine's improvements. Finally, conclusions of this study are exposed. PMID:28787882

Hybrid ABC Optimized MARS-Based Modeling of the Milling Tool Wear from Milling Run Experimental Data.

PubMed

García Nieto, Paulino José; García-Gonzalo, Esperanza; Ordóñez Galán, Celestino; Bernardo Sánchez, Antonio

2016-01-28

Milling cutters are important cutting tools used in milling machines to perform milling operations, which are prone to wear and subsequent failure. In this paper, a practical new hybrid model to predict the milling tool wear in a regular cut, as well as entry cut and exit cut, of a milling tool is proposed. The model was based on the optimization tool termed artificial bee colony (ABC) in combination with multivariate adaptive regression splines (MARS) technique. This optimization mechanism involved the parameter setting in the MARS training procedure, which significantly influences the regression accuracy. Therefore, an ABC-MARS-based model was successfully used here to predict the milling tool flank wear (output variable) as a function of the following input variables: the time duration of experiment, depth of cut, feed, type of material, etc . Regression with optimal hyperparameters was performed and a determination coefficient of 0.94 was obtained. The ABC-MARS-based model's goodness of fit to experimental data confirmed the good performance of this model. This new model also allowed us to ascertain the most influential parameters on the milling tool flank wear with a view to proposing milling machine's improvements. Finally, conclusions of this study are exposed.

Study on the effectiveness of Extreme Cold Mist MQL system on turning process of stainless steel AISI 316

NASA Astrophysics Data System (ADS)

Jamaludin, A. S.; Hosokawa, A.; Furumoto, T.; Koyano, T.; Hashimoto, Y.

2018-03-01

Cutting process of difficult-to-cut material such as stainless steel, generates immensely excessive heat, which is one of the major causes related to shortening tool life and lower quality of surface finish. It is proven that application of cutting fluid during the cutting process of difficult-to-cut material is able to improve the cutting performance, but excessive application of cutting fluid leads to another problem such as increasing processing cost and environmental hazardous pollution of workplace. In the study, Extreme Cold Mist system is designed and tested along with various Minimum Quantity Lubrication (MQL) systems on turning process of stainless steel AISI 316. In the study, it is obtained that, Extreme Cold Mist system is able to reduce cutting force up to 60N and improve the surface roughness of the machined surface significantly.

Fundamentals of cutting.

PubMed

Williams, J G; Patel, Y

2016-06-06

The process of cutting is analysed in fracture mechanics terms with a view to quantifying the various parameters involved. The model used is that of orthogonal cutting with a wedge removing a layer of material or chip. The behaviour of the chip is governed by its thickness and for large radii of curvature the chip is elastic and smooth cutting occurs. For smaller thicknesses, there is a transition, first to plastic bending and then to plastic shear for small thicknesses and smooth chips are formed. The governing parameters are tool geometry, which is principally the wedge angle, and the material properties of elastic modulus, yield stress and fracture toughness. Friction can also be important. It is demonstrated that the cutting process may be quantified via these parameters, which could be useful in the study of cutting in biology.

Evaluation of Process Performance for Sustainable Hard Machining

NASA Astrophysics Data System (ADS)

Rotella, Giovanna; Umbrello, Domenico; , Oscar W. Dillon, Jr.; Jawahir, I. S.

This paper aims to evaluate the sustainability performance of machining operation of through-hardening steel, AISI 52100, taking into account the impact of the material removal process in its various aspects. Experiments were performed for dry and cryogenic cutting conditions using chamfered cubic boron nitride (CBN) tool inserts at varying cutting conditions (cutting speed and feed rate). Cutting forces, mechanical power, tool wear, white layer thickness, surface roughness and residual stresses were investigated in order to evaluate the effects of extreme in-process cooling on the machined surface. The results indicate that cryogenic cooling has the potential to be used for surface integrity enhancement for improved product life and more sustainable functional performance.

Heat-Assisted Machining for Material Removal Improvement

NASA Astrophysics Data System (ADS)

Mohd Hadzley, A. B.; Hafiz, S. Muhammad; Azahar, W.; Izamshah, R.; Mohd Shahir, K.; Abu, A.

2015-09-01

Heat assisted machining (HAM) is a process where an intense heat source is used to locally soften the workpiece material before machined by high speed cutting tool. In this paper, an HAM machine is developed by modification of small CNC machine with the addition of special jig to hold the heat sources in front of the machine spindle. Preliminary experiment to evaluate the capability of HAM machine to produce groove formation for slotting process was conducted. A block AISI D2 tool steel with100mm (width) × 100mm (length) × 20mm (height) size has been cut by plasma heating with different setting of arc current, feed rate and air pressure. Their effect has been analyzed based on distance of cut (DOC).Experimental results demonstrated the most significant factor that contributed to the DOC is arc current, followed by the feed rate and air pressure. HAM improves the slotting process of AISI D2 by increasing distance of cut due to initial cutting groove that formed during thermal melting and pressurized air from the heat source.

Experimental investigation on hard turning of AISI 4340 steel using cemented coated carbide insert

NASA Astrophysics Data System (ADS)

Pradeep Kumar, J.; Kishore, K. P.; Ranjith Kumar, M.; Saran Karthick, K. R.; Vishnu Gowtham, S.

2018-02-01

Hard turning is a developing technology that offers many potential advantages compared to grinding, which remains the standard finishing process for critical hardened surfaces. In this work, an attempt has been made to experimentally investigate hard turning of AISI 4340 steel under wet and dry condition using cemented coated carbide insert. Hardness of the workpiece material is tested using Brinell and Rockwell hardness testers. CNC LATHE and cemented coated carbide inserts of designation CNMG 120408 are used for conducting experimental trials. Significant cutting parameters like cutting speed, feed rate and depth of cut are considered as controllable input parameters and surface roughness (Ra), tool wear are considered as output response parameters. Design of experiments is carried out with the help of Taguchi’s L9 orthogonal array. Results of response parameters like surface roughness and tool wear under wet and dry condition are analysed. It is found that surface roughness and tool wear are higher under dry machining condition when compared to wet machining condition. Feed rate significantly influences the surface roughness followed by cutting speed. Depth of cut significantly influences the tool wear followed by cutting speed.

The effects of cutting parameters on cutting forces and heat generation when drilling animal bone and biomechanical test materials.

PubMed

Cseke, Akos; Heinemann, Robert

2018-01-01

The research presented in this paper investigated the effects of spindle speed and feed rate on the resultant cutting forces (thrust force and torque) and temperatures while drilling SawBones ® biomechanical test materials and cadaveric cortical bone (bovine and porcine femur) specimens. It also investigated cortical bone anisotropy on the cutting forces, when drilling in axial and radial directions. The cutting forces are only affected by the feed rate, whereas the cutting temperature in contrast is affected by both spindle speed and feed rate. The temperature distribution indicates friction as the primary heat source, which is caused by the rubbing of the tool margins and the already cut chips over the borehole wall. Cutting forces were considerably higher when drilling animal cortical bone, in comparison to cortical test material. Drilling direction, and therewith anisotropy, appears to have a negligible effect on the cutting forces. The results suggest that this can be attributed to the osteons being cut at an angle rather than in purely axial or radial direction, as a result of a twist drill's point angle. Copyright © 2017 IPEM. Published by Elsevier Ltd. All rights reserved.

Deposition Of Cubic BN On Diamond Interlayers

NASA Technical Reports Server (NTRS)

Ong, Tiong P.; Shing, Yuh-Han

1994-01-01

Thin films of polycrystalline, pure, cubic boron nitride (c-BN) formed on various substrates, according to proposal, by chemical vapor deposition onto interlayers of polycrystalline diamond. Substrate materials include metals, semiconductors, and insulators. Typical substrates include metal-cutting tools: polycrystalline c-BN coats advantageous for cutting ferrous materials and for use in highly oxidizing environments-applications in which diamond coats tend to dissolve in iron or be oxidized, respectively.

The use of cutting temperature to evaluate the machinability of titanium alloys.

PubMed

Kikuchi, Masafumi

2009-02-01

This study investigated the machinability of titanium, two commercial titanium alloys (Ti-6Al-4V and Ti-6Al-7Nb) and free-cutting brass using the cutting temperature. The cutting temperature was estimated by measuring the thermal electromotive force of the tool-workpiece thermocouple during cutting. The thermoelectric power of each metal relative to the tool had previously been determined. The metals were slotted using a milling machine and carbide square end mills under four cutting conditions. The cutting temperatures of Ti-6Al-4V and Ti-6Al-7Nb were significantly higher than that of the titanium, while that of the free-cutting brass was lower. This result coincided with the relationship of the magnitude of the cutting forces measured in a previous study. For each metal, the cutting temperature became higher when the depth of cut or the cutting speed and feed increased. The increase in the cutting speed and feed was more influential on the value than the increase in the depth of cut when two cutting conditions with the same removal rates were compared. The results demonstrated that cutting temperature measurement can be utilized to develop a new material for dental CAD/CAM applications and to optimize the cutting conditions.

Study on Platinum Coating Depth in Focused Ion Beam Diamond Cutting Tool Milling and Methods for Removing Platinum Layer.

PubMed

Choi, Woong Kirl; Baek, Seung Yub

2015-09-22

In recent years, nanomachining has attracted increasing attention in advanced manufacturing science and technologies as a value-added processes to control material structures, components, devices, and nanoscale systems. To make sub-micro patterns on these products, micro/nanoscale single-crystal diamond cutting tools are essential. Popular non-contact methods for the macro/micro processing of diamond composites are pulsed laser ablation (PLA) and electric discharge machining (EDM). However, for manufacturing nanoscale diamond tools, these machining methods are not appropriate. Despite diamond's extreme physical properties, diamond can be micro/nano machined relatively easily using a focused ion beam (FIB) technique. In the FIB milling process, the surface properties of the diamond cutting tool is affected by the amorphous damage layer caused by the FIB gallium ion collision and implantation and these influence the diamond cutting tool edge sharpness and increase the processing procedures. To protect the diamond substrate, a protection layer-platinum (Pt) coating is essential in diamond FIB milling. In this study, the depth of Pt coating layer which could decrease process-induced damage during FIB fabrication is investigated, along with methods for removing the Pt coating layer on diamond tools. The optimum Pt coating depth has been confirmed, which is very important for maintaining cutting tool edge sharpness and decreasing processing procedures. The ultra-precision grinding method and etching with aqua regia method have been investigated for removing the Pt coating layer. Experimental results show that when the diamond cutting tool width is bigger than 500 nm, ultra-precision grinding method is appropriate for removing Pt coating layer on diamond tool. However, the ultra-precision grinding method is not recommended for removing the Pt coating layer when the cutting tool width is smaller than 500 nm, because the possibility that the diamond cutting tool is damaged by the grinding process will be increased. Despite the etching method requiring more procedures to remove the Pt coating layer after FIB milling, it is a feasible method for diamond tools with under 500 nm width.

An experimental investigation on orthogonal cutting of hybrid CFRP/Ti stacks

NASA Astrophysics Data System (ADS)

Xu, Jinyang; El Mansori, Mohamed

2016-10-01

Hybrid CFRP/Ti stack has been widely used in the modern aerospace industry owing to its superior mechanical/physical properties and excellent structural functions. Several applications require mechanical machining of these hybrid composite stacks in order to achieve dimensional accuracy and assembly performance. However, machining of such composite-to-metal alliance is usually an extremely challenging task in the manufacturing sectors due to the disparate natures of each stacked constituent and their respective poor machinability. Special issues may arise from the high force/heat generation, severe subsurface damage and rapid tool wear. To study the fundamental mechanisms controlling the bi-material machining, this paper presented an experimental study on orthogonal cutting of hybrid CFRP/Ti stack by using superior polycrystalline diamond (PCD) tipped tools. The utilized cutting parameters for hybrid CFRP/Ti machining were rigorously adopted through a compromise selection due to the disparate machinability behaviors of the CFRP laminate and Ti alloy. The key cutting responses in terms of cutting force generation, machined surface quality and tool wear mechanism were precisely addressed. The experimental results highlighted the involved five stages of CFRP/Ti cutting and the predominant crater wear and edge fracture failure governing the PCD cutting process.

A review of cutting mechanics and modeling techniques for biological materials.

PubMed

Takabi, Behrouz; Tai, Bruce L

2017-07-01

This paper presents a comprehensive survey on the modeling of tissue cutting, including both soft tissue and bone cutting processes. In order to achieve higher accuracy in tissue cutting, as a critical process in surgical operations, the meticulous modeling of such processes is important in particular for surgical tool development and analysis. This review paper is focused on the mechanical concepts and modeling techniques utilized to simulate tissue cutting such as cutting forces and chip morphology. These models are presented in two major categories, namely soft tissue cutting and bone cutting. Fracture toughness is commonly used to describe tissue cutting while Johnson-Cook material model is often adopted for bone cutting in conjunction with finite element analysis (FEA). In each section, the most recent mathematical and computational models are summarized. The differences and similarities among these models, challenges, novel techniques, and recommendations for future work are discussed along with each section. This review is aimed to provide a broad and in-depth vision of the methods suitable for tissue and bone cutting simulations. Copyright © 2017 IPEM. Published by Elsevier Ltd. All rights reserved.

Estimation of the influence of tool wear on force signals: A finite element approach in AISI 1045 orthogonal cutting

NASA Astrophysics Data System (ADS)

Equeter, Lucas; Ducobu, François; Rivière-Lorphèvre, Edouard; Abouridouane, Mustapha; Klocke, Fritz; Dehombreux, Pierre

2018-05-01

Industrial concerns arise regarding the significant cost of cutting tools in machining process. In particular, their improper replacement policy can lead either to scraps, or to early tool replacements, which would waste fine tools. ISO 3685 provides the flank wear end-of-life criterion. Flank wear is also the nominal type of wear for longest tool lifetimes in optimal cutting conditions. Its consequences include bad surface roughness and dimensional discrepancies. In order to aid the replacement decision process, several tool condition monitoring techniques are suggested. Force signals were shown in the literature to be strongly linked with tools flank wear. It can therefore be assumed that force signals are highly relevant for monitoring the condition of cutting tools and providing decision-aid information in the framework of their maintenance and replacement. The objective of this work is to correlate tools flank wear with numerically computed force signals. The present work uses a Finite Element Model with a Coupled Eulerian-Lagrangian approach. The geometry of the tool is changed for different runs of the model, in order to obtain results that are specific to a certain level of wear. The model is assessed by comparison with experimental data gathered earlier on fresh tools. Using the model at constant cutting parameters, force signals under different tool wear states are computed and provide force signals for each studied tool geometry. These signals are qualitatively compared with relevant data from the literature. At this point, no quantitative comparison could be performed on worn tools because the reviewed literature failed to provide similar studies in this material, either numerical or experimental. Therefore, further development of this work should include experimental campaigns aiming at collecting cutting forces signals and assessing the numerical results that were achieved through this work.

Optimization of multi response in end milling process of ASSAB XW-42 tool steel with liquid nitrogen cooling using Taguchi-grey relational analysis

NASA Astrophysics Data System (ADS)

Norcahyo, Rachmadi; Soepangkat, Bobby O. P.

2017-06-01

A research was conducted for the optimization of the end milling process of ASSAB XW-42 tool steel with multiple performance characteristics based on the orthogonal array with Taguchi-grey relational analysis method. Liquid nitrogen was applied as a coolant. The experimental studies were conducted under varying the liquid nitrogen cooling flow rates (FL), and the end milling process variables, i.e., cutting speed (Vc), feeding speed (Vf), and axial depth of cut (Aa). The optimized multiple performance characteristics were surface roughness (SR), flank wear (VB), and material removal rate (MRR). An orthogonal array, signal-to-noise (S/N) ratio, grey relational analysis, grey relational grade, and analysis of variance were employed to study the multiple performance characteristics. Experimental results showed that flow rate gave the highest contribution for reducing the total variation of the multiple responses, followed by cutting speed, feeding speed, and axial depth of cut. The minimum surface roughness, flank wear, and maximum material removal rate could be obtained by using the values of flow rate, cutting speed, feeding speed, and axial depth of cut of 0.5 l/minute, 109.9 m/minute, 440 mm/minute, and 0.9 mm, respectively.

Development of a Numerical Model for Orthogonal Cutting. Discussion about the Sensitivity to Friction Problem

NASA Astrophysics Data System (ADS)

San Juan, M.; de la Iglesia, J. M.; Martín, O.; Santos, F. J.

2009-11-01

In despite of the important progresses achieved in the knowledge of cutting processes, the study of certain aspects has undergone the very limitations of the experimental means: temperature gradients, frictions, contact, etc… Therefore, the development of numerical models is a valid tool as a first approach to study of those problems. In the present work, a calculation model under Abaqus Explicit code is developed to represent the orthogonal cutting of AISI 4140 steel. A bidimensional simulation under plane strain conditions, which is considered as adiabatic due to the high speed of the material flow, is chosen. The chip separation is defined by means of a fracture law that allows complex simulations of tool penetration in the workpiece. The strong influence of friction on cutting is proved, therefore a very good definition of materials behaviour laws could be obtained, but an erroneous value of friction coefficient could notably reduce the reliability. Considering the difficulty of checking the friction models used in the simulation, from the tests carried out habitually, the most efficacious way to characterize the friction would be to combine simulation models with cutting tests.

Machinability of CAD-CAM materials.

PubMed

Chavali, Ramakiran; Nejat, Amir H; Lawson, Nathaniel C

2017-08-01

Although new materials are available for computer-aided design and computer-aided manufacturing (CAD-CAM) fabrication, limited information is available regarding their machinability. The depth of penetration of a milling tool into a material during a timed milling cycle may indicate its machinability. The purpose of this in vitro study was to compare the tool penetration rate for 2 polymer-containing CAD-CAM materials (Lava Ultimate and Enamic) and 2 ceramic-based CAD-CAM materials (e.max CAD and Celtra Duo). The materials were sectioned into 4-mm-thick specimens (n=5/material) and polished with 320-grit SiC paper. Each specimen was loaded into a custom milling apparatus. The apparatus pushed the specimens against a milling tool (E4D Tapered 2016000) rotating at 40 000 RPM with a constant force of 0.98 N. After a 6-minute timed milling cycle, the length of each milling cut was measured with image analysis software under a digital light microscope. Representative specimens and milling tools were examined with scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy. The penetration rate of Lava Ultimate (3.21 ±0.46 mm/min) and Enamic (2.53 ±0.57 mm/min) was significantly greater than that of e.max CAD (1.12 ±0.32 mm/min) or Celtra Duo (0.80 ±0.21 mm/min) materials. SEM observations showed little tool damage, regardless of material type. Residual material was found on the tools used with polymer-containing materials, and wear of the embedding medium was seen on the tools used with the ceramic-based materials. Edge chipping was noted on cuts made in the ceramic-based materials. Lava Ultimate and Enamic have greater machinability and less edge chipping than e.max CAD and Celtra Duo. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Controlling the type and the form of chip when machining steel

NASA Astrophysics Data System (ADS)

Gruby, S. V.; Lasukov, A. A.; Nekrasov, R. Yu; Politsinsky, E. V.; Arkhipova, D. A.

2016-08-01

The type of the chip produced in the process of machining influences many factors of production process. Controlling the type of chip when cutting metals is important for producing swarf chips and for easing its utilization as well as for protecting the machined surface, cutting tool and the worker. In the given work we provide the experimental data on machining structural steel with implanted tool. The authors show that it is possible to control the chip formation process to produce the required type of chip by selecting the material for machining the tool surface.

Cutting Modeling of Hybrid CFRP/Ti Composite with Induced Damage Analysis

PubMed Central

Xu, Jinyang; El Mansori, Mohamed

2016-01-01

In hybrid carbon fiber reinforced polymer (CFRP)/Ti machining, the bi-material interface is the weakest region vulnerable to severe damage formation when the tool cutting from one phase to another phase and vice versa. The interface delamination as well as the composite-phase damage is the most serious failure dominating the bi-material machining. In this paper, an original finite element (FE) model was developed to inspect the key mechanisms governing the induced damage formation when cutting this multi-phase material. The hybrid composite model was constructed by establishing three disparate physical constituents, i.e., the Ti phase, the interface, and the CFRP phase. Different constitutive laws and damage criteria were implemented to build up the entire cutting behavior of the bi-material system. The developed orthogonal cutting (OC) model aims to characterize the dynamic mechanisms of interface delamination formation and the affected interface zone (AIZ). Special focus was made on the quantitative analyses of the parametric effects on the interface delamination and composite-phase damage. The numerical results highlighted the pivotal role of AIZ in affecting the formation of interface delamination, and the significant impacts of feed rate and cutting speed on delamination extent and fiber/matrix failure. PMID:28787824

The development of Zirconia and Copper toughened Alumina ceramic insert

NASA Astrophysics Data System (ADS)

Amalina Sabuan, Nur; Zolkafli, Nurfatini; Mebrahitom, A.; Azhari, Azmir; Mamat, Othman

2018-04-01

Ceramic cutting tools have been utilized in industry for over a century for its productivity and efficiency in machine tools and cutting tool material. However, due to the brittleness property the application has been limited. In order to manufacture high strength ceramic cutting tools, there is a need for suitable reinforcement to improve its toughness. In this case, copper (Cu) and zirconia (ZrO2) powders were added to investigate the hardness and physical properties of the developed composite insert. A uniaxial pre-forming process of the mix powder was done prior to densification by sintering at 1000 and 1300°C. The effect of the composition of the reinforcement on the hardness, density, shrinkage and microstructure of the inserts was investigated. It was found that an optimum density of 3.26 % and hardness 1385HV was obtained for composite of 10wt % zirconia and 10wt% copper at temperature 1000 °C.

Diamond- cBN alloy: A universal cutting material

DOE PAGES

Wang, Pei; He, Duanwei; Wang, Liping; ...

2015-09-08

Diamond and cubic boron nitride ( cBN) as conventional superhard materials have found widespread industrial applications, but both have inherent limitations. Diamond is not suitable for high-speed cutting of ferrous materials due to its poor chemical inertness, while cBN is only about half as hard as diamond. Because of their affinity in structural lattices and covalent bonding character, diamond and cBN could form alloys that can potentially fill the performance gap. However, the idea has never been demonstrated because samples obtained in the previous studies were too small to be tested for their practical performance. Here, we report the synthesismore » and characterization of transparent bulk diamond- cBN alloy compacts whose diameters (3 mm) are sufficiently large for them to be processed into cutting tools. The testing results show that the diamond- cBN alloy has superior chemical inertness over polycrystalline diamond and higher hardness than single crystal cBN. In conclusion, high-speed cutting tests on hardened steel and granite suggest that diamond- cBN alloy is indeed a universal cutting material.« less

Diamond-cBN alloy: A universal cutting material

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Pei; High Pressure Science and Engineering Center and Department of Physics and Astronomy, University of Nevada Las Vegas, Las Vegas, Nevada 89154; He, Duanwei, E-mail: duanweihe@scu.edu.cn

Diamond and cubic boron nitride (cBN) as conventional superhard materials have found widespread industrial applications, but both have inherent limitations. Diamond is not suitable for high-speed cutting of ferrous materials due to its poor chemical inertness, while cBN is only about half as hard as diamond. Because of their affinity in structural lattices and covalent bonding character, diamond and cBN could form alloys that can potentially fill the performance gap. However, the idea has never been demonstrated because samples obtained in the previous studies were too small to be tested for their practical performance. Here, we report the synthesis andmore » characterization of transparent bulk diamond-cBN alloy compacts whose diameters (3 mm) are sufficiently large for them to be processed into cutting tools. The testing results show that the diamond-cBN alloy has superior chemical inertness over polycrystalline diamond and higher hardness than single crystal cBN. High-speed cutting tests on hardened steel and granite suggest that diamond-cBN alloy is indeed a universal cutting material.« less

Diamond- cBN alloy: A universal cutting material

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Pei; He, Duanwei; Wang, Liping

Diamond and cubic boron nitride ( cBN) as conventional superhard materials have found widespread industrial applications, but both have inherent limitations. Diamond is not suitable for high-speed cutting of ferrous materials due to its poor chemical inertness, while cBN is only about half as hard as diamond. Because of their affinity in structural lattices and covalent bonding character, diamond and cBN could form alloys that can potentially fill the performance gap. However, the idea has never been demonstrated because samples obtained in the previous studies were too small to be tested for their practical performance. Here, we report the synthesismore » and characterization of transparent bulk diamond- cBN alloy compacts whose diameters (3 mm) are sufficiently large for them to be processed into cutting tools. The testing results show that the diamond- cBN alloy has superior chemical inertness over polycrystalline diamond and higher hardness than single crystal cBN. In conclusion, high-speed cutting tests on hardened steel and granite suggest that diamond- cBN alloy is indeed a universal cutting material.« less

Caracterisation of Titanium Nitride Layers Deposited by Reactive Plasma Spraying

NASA Astrophysics Data System (ADS)

Roşu, Radu Alexandru; Şerban, Viorel-Aurel; Bucur, Alexandra Ioana; Popescu, Mihaela; Uţu, Dragoş

2011-01-01

Forming and cutting tools are subjected to the intense wear solicitations. Usually, they are either subject to superficial heat treatments or are covered with various materials with high mechanical properties. In recent years, thermal spraying is used increasingly in engineering area because of the large range of materials that can be used for the coatings. Titanium nitride is a ceramic material with high hardness which is used to cover the cutting tools increasing their lifetime. The paper presents the results obtained after deposition of titanium nitride layers by reactive plasma spraying (RPS). As deposition material was used titanium powder and as substratum was used titanium alloy (Ti6Al4V). Macroscopic and microscopic (scanning electron microscopy) images of the deposited layers and the X ray diffraction of the coatings are presented. Demonstration program with layers deposited with thickness between 68,5 and 81,4 μm has been achieved and presented.

Rotary ultrasonic machining of CFRP: a mechanistic predictive model for cutting force.

PubMed

Cong, W L; Pei, Z J; Sun, X; Zhang, C L

2014-02-01

Cutting force is one of the most important output variables in rotary ultrasonic machining (RUM) of carbon fiber reinforced plastic (CFRP) composites. Many experimental investigations on cutting force in RUM of CFRP have been reported. However, in the literature, there are no cutting force models for RUM of CFRP. This paper develops a mechanistic predictive model for cutting force in RUM of CFRP. The material removal mechanism of CFRP in RUM has been analyzed first. The model is based on the assumption that brittle fracture is the dominant mode of material removal. CFRP micromechanical analysis has been conducted to represent CFRP as an equivalent homogeneous material to obtain the mechanical properties of CFRP from its components. Based on this model, relationships between input variables (including ultrasonic vibration amplitude, tool rotation speed, feedrate, abrasive size, and abrasive concentration) and cutting force can be predicted. The relationships between input variables and important intermediate variables (indentation depth, effective contact time, and maximum impact force of single abrasive grain) have been investigated to explain predicted trends of cutting force. Experiments are conducted to verify the model, and experimental results agree well with predicted trends from this model. Copyright © 2013 Elsevier B.V. All rights reserved.

Autoresonant control of nonlinear mode in ultrasonic transducer for machining applications.

PubMed

Babitsky, V I; Astashev, V K; Kalashnikov, A N

2004-04-01

Experiments conducted in several countries have shown that the improvement of machining quality can be promoted through conversion of the cutting process into one involving controllable high-frequency vibration at the cutting zone. This is achieved through the generation and maintenance of ultrasonic vibration of the cutting tool to alter the fracture process of work-piece material cutting to one in which loading of the materials at the tool tip is incremental, repetitive and controlled. It was shown that excitation of the high-frequency vibro-impact mode of the tool-workpiece interaction is the most effective way of ultrasonic influence on the dynamic characteristics of machining. The exploitation of this nonlinear mode needs a new method of adaptive control for excitation and stabilisation of ultrasonic vibration known as autoresonance. An approach has been developed to design an autoresonant ultrasonic cutting unit as an oscillating system with an intelligent electronic feedback controlling self-excitation in the entire mechatronic system. The feedback produces the exciting force by means of transformation and amplification of the motion signal. This allows realisation for robust control of fine resonant tuning to bring the nonlinear high Q-factor systems into technological application. The autoresonant control provides the possibility of self-tuning and self-adaptation mechanisms for the system to keep the nonlinear resonant mode of oscillation under unpredictable variation of load, structure and parameters. This allows simple regulation of intensity of the process whilst keeping maximum efficiency at all times. An autoresonant system with supervisory computer control was developed, tested and used for the control of the piezoelectric transducer during ultrasonically assisted cutting. The system has been developed as combined analog-digital, where analog devices process the control signal, and parameters of the devices are controlled digitally by computer. The system was applied for advanced machining of aviation materials.

Performance of Metal Cutting on Endmills Manufactured by Cooling-Air and Minimum Quantity Lubrication Grinding

NASA Astrophysics Data System (ADS)

Inoue, Shigeru; Aoyama, Tojiro

Grinding fluids have been commonly used during the grinding of tools for their cooling and lubricating effect since the hard, robust materials used for cutting tools are difficult to grind. Grinding fluids help prevent a drop in hardness due to burning of the cutting edge and keep chipping to an absolute minimum. However, there is a heightened awareness of the need to improve the work environment and protect the global environment. Thus, the present study is aimed at applying dry grinding, cooling-air grinding, cooling-air grinding with minimum quantity lubrication (MQL), and oil-based fluid grinding to manufacturing actual endmills (HSS-Co). Cutting tests were performed by a vertical machining center. The results indicated that the lowest surface inclination values and longest tool life were obtained by cooling-air grinding with MQL. Thus, cooling-air grinding with MQL has been demonstrated to be at least as effective as oil-based fluid grinding.

Experimental Parametric Model for Indirect Adhesion Wear Measurement in the Dry Turning of UNS A97075 (Al-Zn) Alloy

PubMed Central

Trujillo, Francisco Javier; Sevilla, Lorenzo; Marcos, Mariano

2017-01-01

In this work, the study of the influence of cutting parameters (cutting speed, feed, and depth of cut) on the tool wear used in in the dry turning of cylindrical bars of the UNS A97075 (Al-Zn) alloy, has been analyzed. In addition, a study of the physicochemical mechanisms of the secondary adhesion wear has been carried out. The behavior of this alloy, from the point of view of tool wear, has been compared to similar aeronautical aluminum alloys, such as the UNS A92024 (Al-Cu) alloy and UNS A97050 (Al-Zn) alloy. Furthermore, a first approach to the measurement of the 2D surface of the adhered material on the rake face of the tool has been conducted. Finally, a parametric model has been developed from the experimental results. This model allows predicting the intensity of the secondary adhesion wear as a function of the cutting parameters applied. PMID:28772510

Angular analysis of the cyclic impacting oscillations in a robotic grinding process

NASA Astrophysics Data System (ADS)

Rafieian, Farzad; Girardin, François; Liu, Zhaoheng; Thomas, Marc; Hazel, Bruce

2014-02-01

In a robotic machining process, a light-weight cutter or grinder is usually held by an articulated robot arm. Material removal is achieved by the rotating cutting tool while the robot end effector ensures that the tool follows a programmed trajectory in order to work on complex curved surfaces or to access hard-to-reach areas. One typical application of such process is maintenance and repair work on hydropower equipment. This paper presents an experimental study of the dynamic characteristics of material removal in robotic grinding, which is unlike conventional grinding due to the lower structural stiffness of the tool-holder robot. The objective of the study is to explore the cyclic nature of this mechanical operation to provide the basis for future development of better process control strategies. Grinding tasks that minimize the number of iterations to converge to the target surface can be better planned based on a good understanding and modeling of the cyclic material removal mechanism. A single degree of freedom dynamic analysis of the process suggests that material removal is performed through high-frequency impacts that mainly last for only a small fraction of the grinding disk rotation period. To detect these discrete cutting events in practice, a grinder is equipped with a rotary encoder. The encoder's signal is acquired through the angular sampling technique. A running cyclic synchronous average is applied to the speed signal to remove its non-cyclic events. The measured instantaneous rotational frequency clearly indicates the impacting nature of the process and captures the transient response excited by these cyclic impacts. The technique also locates the angular positions of cutting impacts in revolution cycles. It is thus possible to draw conclusions about the cyclic nature of dynamic changes in impact-cutting behavior when grinding with a flexible robot. The dynamics of the impacting regime and transient responses to impact-cutting excitations captured synchronously using the angular sampling technique provide feedback that can be used to regulate the material removal process. The experimental results also make it possible to correlate the energy required to remove a chip of metal through impacting with the measured drop in angular speed during grinding.

Aspects of ultra-high-precision diamond machining of RSA 443 optical aluminium

NASA Astrophysics Data System (ADS)

Mkoko, Z.; Abou-El-Hossein, K.

2015-08-01

Optical aluminium alloys such as 6061-T6 are traditionally used in ultra-high precision manufacturing for making optical mirrors for aerospace and other applications. However, the optics industry has recently witnessed the development of more advanced optical aluminium grades that are capable of addressing some of the issues encountered when turning with single-point natural monocrystalline diamond cutters. The advent of rapidly solidified aluminium (RSA) grades has generally opened up new possibilities for ultra-high precision manufacturing of optical components. In this study, experiments were conducted with single-point diamond cutters on rapidly solidified aluminium RSA 443 material. The objective of this study is to observe the effects of depth of cut and feed rate at a fixed rotational speed on the tool wear rate and resulting surface roughness of diamond turned specimens. This is done to gain further understanding of the rate of wear on the diamond cutters versus the surface texture generated on the RSA 443 material. The diamond machining experiments yielded machined surfaces which are less reflective but with consistent surface roughness values. Cutting tools were observed for wear through scanning microscopy; relatively low wear pattern was evident on the diamond tool edge. The highest tool wear were obtained at higher depth of cut and increased feed rate.

System technology for laser-assisted milling with tool integrated optics

NASA Astrophysics Data System (ADS)

Hermani, Jan-Patrick; Emonts, Michael; Brecher, Christian

2013-02-01

High strength metal alloys and ceramics offer a huge potential for increased efficiency (e. g. in engine components for aerospace or components for gas turbines). However, mass application is still hampered by cost- and time-consuming end-machining due to long processing times and high tool wear. Laser-induced heating shortly before machining can reduce the material strength and improve machinability significantly. The Fraunhofer IPT has developed and successfully realized a new approach for laser-assisted milling with spindle and tool integrated, co-rotating optics. The novel optical system inside the tool consists of one deflection prism to position the laser spot in front of the cutting insert and one focusing lens. Using a fiber laser with high beam quality the laser spot diameter can be precisely adjusted to the chip size. A high dynamic adaption of the laser power signal according to the engagement condition of the cutting tool was realized in order not to irradiate already machined work piece material. During the tool engagement the laser power is controlled in proportion to the current material removal rate, which has to be calculated continuously. The needed geometric values are generated by a CAD/CAM program and converted into a laser power signal by a real-time controller. The developed milling tool with integrated optics and the algorithm for laser power control enable a multi-axis laser-assisted machining of complex parts.

The use of water-jetting technology in prostheses revision surgery-first results of parameter studies on bone and bone cement.

PubMed

Honl, M; Rentzsch, R; Müller, G; Brandt, C; Bluhm, A; Hille, E; Louis, H; Morlock, M

2000-01-01

Water-jet cutting techniques have been used in industrial applications for many different materials. Recently these techniques have been developed into a revolutionary cutting tool for soft tissues in visceral surgery. The present study investigates the usage of this cutting technology for the revision surgery of endoprostheses. In the first part of the study, samples of bovine bone and acrylic bone cement (PMMA) were cut using an industrial jet cutting device with pure water. Below 400 bar, only PMMA was cut; above 400 bar, bone was also cut, but only pressures above 800 bar resulted in clinically useful rates of material removal (cut depth 2. 4 mm at 10 mm/min traverse speed). In the second part of the study, the effect of adding biocompatible abrasives to the water in order to reduce the required pressure was investigated, resulting in a significantly higher removal of material. At 600 bar, PMMA was cut 5. 2 mm deep with plain water and 15.2 mm deep with added abrasives. The quality of the cuts was increased by the abrasive. Though there was no clear selectivity between bone and PMMA any more, the rate of material removal at similar pressures was significantly higher for PMMA than for bone (600 bar: 1.6 mm cut depth for bone samples, 15.2 mm for PMMA). The measured cut depths with either method were not influenced by a change of the cutting direction with respect to the main direction of the osteons in the bone. However, a reduction of the jet surface angle (90 degrees to 23 degrees ) resulted for bone in a significantly lower cut depth at 600 bar (plain water: 0.62 mm vs. 0.06 mm; abrasive: 1.61 mm vs. 0.60 mm). The laboratory experiments indicate that abrasive water jets may be suitable for cutting biomaterials like bone and bone cement. Copyright 2000 John Wiley & Sons, Inc.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining.

PubMed

Ramulu, M; Spaulding, Mathew

2016-09-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

PubMed Central

Ramulu, M.; Spaulding, Mathew

2016-01-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application. PMID:28773866

Momentum and velocity of the ablated material in laser machining of carbon fiber preforms

NASA Astrophysics Data System (ADS)

Mucha, P.; Speker, N.; Weber, R.; Graf, T.

2013-11-01

The automation in fabrication of CFRP (carbon-fiber-reinforced plastics) parts demands efficient and low-cost machining technologies. In conventional cutting technologies, tool-wear and low process speeds are some of the reasons for high costs. Thus, the use of lasers is an attractive option for cutting CF-preforms. A typical effect degrading the quality in laser cutting CF-preform is a bulged cutting edge. This effect is assumed to be caused by interaction of the fibers with the ablated material, which leaves the kerf at high velocity. Hence, a method for measuring the momentum and the velocity of the vapor is presented in this article. To measure the momentum of the ablated material, the CF-preform is mounted on a precision scale while cutting it with a laser. The direction of the momentum was determined by measuring the momentum parallel and orthogonal to the CF-preform surface. A change of the direction of the momentum with different cutting-speeds is assessed at constant laser-power. Averaged velocities of the ablation products of up to 300 m/s were determined by measuring the ablated mass and the momentum.

Fundamental investigation on influence of external heat on chip formation during thermal assisted machining

NASA Astrophysics Data System (ADS)

Alkali, A. U.; Ginta, T. L.; Abdulrani, A. M.; Elsiti, N. M.

2018-04-01

Various heat sources have been investigated by numerous researchers to reveal machinability benefits of thermally assisted machining (TAM) process. Fewer engineering materials have been tested. In the same vein, those researches continue to demonstrate effective performance of TAM in terms of bulk material removal rate, improved surface finish, prolong tool life and reduction of cutting forces among others. Experimental investigation on the strain-hardenability and flow stress of material removed with respect to increase in temperature in TAM has not been given attention in previous studies. This study investigated the pattern of chip morphology and segmentation giving close attention to influence of external heat source responsible for strain – hardenability of the material removed during TAM and dry machining at room temperature. Full immersion down cut milling was used throughout the machining conditions. Machining was conducted on AISI 316L using uncoated tungsten carbide end mill insert at varying cutting speeds (V) of 50, 79, and 100 m/min, and feed rates (f) of 0.15, 0.25, and 0.4 mm/tooth while the depth of cut was maintained at 0.2mm throughout the machining trials. The analyses of chip formation, segmentations and stain hardenability were carried out by using LMU light microscope, field emission microscopy and micro indentation. The study observed that build up edge is formed when a stagnation zone develops in front of tool tip which give rise to poor thermal gradient for conduction heat to be transferred within the bulk material during dry machining. This promotes varying strain – hardening of the material removed with evident high chips hardness and thickness, whereas TAM circumvents such impairment by softening the shear zone through local preheat.

Machining of Fibre Reinforced Plastic Composite Materials.

PubMed

Caggiano, Alessandra

2018-03-18

Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented.

Machining of Fibre Reinforced Plastic Composite Materials

PubMed Central

2018-01-01

Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented. PMID:29562635

One of possible variants of the organization for recycling lubricate cooling of technological means for small businesses

NASA Astrophysics Data System (ADS)

Rusica, I.; Toca, A.; Stingaci, I.; Scaticailov, S.; Scaticailov, I.; Marinescu, O.; Kosenko, P.

2016-11-01

In the paper we analyze the application lubricate cooling technological environment in the processing of various materials in the past century greatly have increased cutting speed and respectively, has increased productivity [1]. Today, none of production in which anyway is used metal cutting machines of all types (milling, turning, grinding, drilling, etc.) is not without lubricant cooling technological liquid which in turn are designed to reduce cutting force and the load on metal cutting machine tools and machined parts in order to increase durability machine tools and reduce errors of processing details and also in resource energy saving. When using lubricate cooling technological environment reduces the temperature in the cutting zone resulting in higher tool life and the preservation of the surface structure being treated reducing wear of metal parts of the machine. Typically, lubricant cooling process fluids is used without replacing as long as possible not yet beginning to negatively affect the quality of process. However life expectancy lubricate cooling technological environment is limited. According to existing normative acts every kind of lubricate cooling technological environment through certain time must be deleted by from the system and subjected to a recycling. Lubricate cooling technological environment must be disposed of for the following reasons: occurs the microbial and the mechanical pollution cutting fluid, free oil impairs operational characteristics cutting fluid and increases consumption.

Wear Mechanism of Chemical Vapor Deposition (CVD) Carbide Insert in Orthogonal Cutting Ti-6Al-4V ELI at High Cutting Speed

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gusri, A. I.; Che Hassan, C. H.; Jaharah, A. G.

2011-01-17

The performance of Chemical Vapor Deposition (CVD) carbide insert with ISO designation of CCMT 12 04 04 LF, when turning titanium alloys was investigated. There were four layers of coating materials for this insert i.e.TiN-Al2O3-TiCN-TiN. The insert performance was evaluated based on the insert's edge resistant towards the machining parameters used at high cutting speed range of machining Ti-6Al-4V ELI. Detailed study on the wear mechanism at the cutting edge of CVD carbide tools was carried out at cutting speed of 55-95 m/min, feed rate of 0.15-0.35 mm/rev and depth of cut of 0.10-0.20 mm. Wear mechanisms such as abrasivemore » and adhesive were observed on the flank face. Crater wear due to diffusion was also observed on the rake race. The abrasive wear occurred more at nose radius and the fracture on tool were found at the feed rate of 0.35 mm/rev and the depth of cut of 0.20 mm. The adhesion wear takes place after the removal of the coating or coating delaminating. Therefore, adhesion or welding of titanium alloy onto the flank and rake faces demonstrates a strong bond at the workpiece-tool interface.« less

Performance of Ti-multilayer coated tool during machining of MDN431 alloyed steel

NASA Astrophysics Data System (ADS)

Badiger, Pradeep V.; Desai, Vijay; Ramesh, M. R.

2018-04-01

Turbine forgings and other components are required to be high resistance to corrosion and oxidation because which they are highly alloyed with Ni and Cr. Midhani manufactures one of such material MDN431. It's a hard-to-machine steel with high hardness and strength. PVD coated insert provide an answer to problem with its state of art technique on the WC tool. Machinability studies is carried out on MDN431 steel using uncoated and Ti-multilayer coated WC tool insert using Taguchi optimisation technique. During the present investigation, speed (398-625rpm), feed (0.093-0.175mm/rev), and depth of cut (0.2-0.4mm) varied according to Taguchi L9 orthogonal array, subsequently cutting forces and surface roughness (Ra) were measured. Optimizations of the obtained results are done using Taguchi technique for cutting forces and surface roughness. Using Taguchi technique linear fit model regression analysis carried out for the combination of each input variable. Experimented results are compared and found the developed model is adequate which supported by proof trials. Speed, feed and depth of cut are linearly dependent on the cutting force and surface roughness for uncoated insert whereas Speed and depth of cut feed is inversely dependent in coated insert for both cutting force and surface roughness. Machined surface for coated and uncoated inserts during machining of MDN431 is studied using optical profilometer.

Wear Mechanism of Chemical Vapor Deposition (CVD) Carbide Insert in Orthogonal Cutting Ti-6Al-4V ELI at High Cutting Speed

NASA Astrophysics Data System (ADS)

Gusri, A. I.; Che Hassan, C. H.; Jaharah, A. G.

2011-01-01

The performance of Chemical Vapor Deposition (CVD) carbide insert with ISO designation of CCMT 12 04 04 LF, when turning titanium alloys was investigated. There were four layers of coating materials for this insert i.e.TiN-Al2O3-TiCN-TiN. The insert performance was evaluated based on the insert's edge resistant towards the machining parameters used at high cutting speed range of machining Ti-6Al-4V ELI. Detailed study on the wear mechanism at the cutting edge of CVD carbide tools was carried out at cutting speed of 55-95 m/min, feed rate of 0.15-0.35 mm/rev and depth of cut of 0.10-0.20 mm. Wear mechanisms such as abrasive and adhesive were observed on the flank face. Crater wear due to diffusion was also observed on the rake race. The abrasive wear occurred more at nose radius and the fracture on tool were found at the feed rate of 0.35 mm/rev and the depth of cut of 0.20 mm. The adhesion wear takes place after the removal of the coating or coating delaminating. Therefore, adhesion or welding of titanium alloy onto the flank and rake faces demonstrates a strong bond at the workpiece-tool interface.

Methods to Predict Stresses in Cutting Inserts Brazed Using Iron-Carbon Brazing Alloy

NASA Astrophysics Data System (ADS)

Konovodov, V. V.; Valentov, A. V.; Retuynskiy, O. Yu; Esekuev, Sh B.

2016-04-01

This work describes a method for predicting residual and operating stresses in a flat-form tool insert made of tungsten free carbides brazed using iron-carbon alloy. According to the studies’ results it is concluded that the recommendations relating to the limitation of a melting point of tool brazing alloys (950-1100°C according to different data) are connected with a negative impact on tools as a composite made of dissimilar materials rather than on hard alloys as a tool material. Due to the cooling process stresses inevitably occur in the brazed joint of dissimilar materials, and these stresses increase with the higher solidification temperature of the brazing alloy.

A Review on High-Speed Machining of Titanium Alloys

NASA Astrophysics Data System (ADS)

Rahman, Mustafizur; Wang, Zhi-Gang; Wong, Yoke-San

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.

Analysis of the temperature of the hot tool in the cut of woven fabric using infrared images

NASA Astrophysics Data System (ADS)

Borelli, Joao E.; Verderio, Leonardo A.; Gonzaga, Adilson; Ruffino, Rosalvo T.

2001-03-01

Textile manufacture occupies a prominence place in the national economy. By virtue of its importance researches have been made on the development of new materials, equipment and methods used in the production process. The cutting of textiles starts in the basic stage, to be followed within the process of the making of clothes and other articles. In the hot cutting of fabric, one of the variables of great importance in the control of the process is the contact temperature between the tool and the fabric. The work presents a technique for the measurement of the temperature based on the processing of infrared images. For this a system was developed composed of an infrared camera, a framegrabber PC board and software that analyzes the punctual temperature in the cut area enabling the operator to achieve the necessary control of the other variables involved in the process.

Tool geometry and damage mechanisms influencing CNC turning efficiency of Ti6Al4V

NASA Astrophysics Data System (ADS)

Suresh, Sangeeth; Hamid, Darulihsan Abdul; Yazid, M. Z. A.; Nasuha, Nurdiyanah; Ain, Siti Nurul

2017-12-01

Ti6Al4V or Grade 5 titanium alloy is widely used in the aerospace, medical, automotive and fabrication industries, due to its distinctive combination of mechanical and physical properties. Ti6Al4V has always been perverse during its machining, strangely due to the same mix of properties mentioned earlier. Ti6Al4V machining has resulted in shorter cutting tool life which has led to objectionable surface integrity and rapid failure of the parts machined. However, the proven functional relevance of this material has prompted extensive research in the optimization of machine parameters and cutting tool characteristics. Cutting tool geometry plays a vital role in ensuring dimensional and geometric accuracy in machined parts. In this study, an experimental investigation is actualized to optimize the nose radius and relief angles of the cutting tools and their interaction to different levels of machining parameters. Low elastic modulus and thermal conductivity of Ti6Al4V contribute to the rapid tool damage. The impact of these properties over the tool tips damage is studied. An experimental design approach is utilized in the CNC turning process of Ti6Al4V to statistically analyze and propose optimum levels of input parameters to lengthen the tool life and enhance surface characteristics of the machined parts. A greater tool nose radius with a straight flank, combined with low feed rates have resulted in a desirable surface integrity. The presence of relief angle has proven to aggravate tool damage and also dimensional instability in the CNC turning of Ti6Al4V.

Development of Anthropometric Analogous Headforms. Phase 1.

DTIC Science & Technology

1994-10-31

shown in figure 5. This surface mesh can then be transformed into polygon faces that are able to be rendered by the AutoCAD rendering tools . Rendering of...computer-generated surfaces. The material removal techniques require the programming of the tool path of the cutter and in some cases requires specialized... tooling . Tool path programs are available to transfer the computer-generated surface into actual paths of the cutting tool . In cases where the

Modeling of Particle Emission During Dry Orthogonal Cutting

NASA Astrophysics Data System (ADS)

Khettabi, Riad; Songmene, Victor; Zaghbani, Imed; Masounave, Jacques

2010-08-01

Because of the risks associated with exposure to metallic particles, efforts are being put into controlling and reducing them during the metal working process. Recent studies by the authors involved in this project have presented the effects of cutting speeds, workpiece material, and tool geometry on particle emission during dry machining; the authors have also proposed a new parameter, named the dust unit ( D u), for use in evaluating the quantity of particle emissions relative to the quantity of chips produced during a machining operation. In this study, a model for predicting the particle emission (dust unit) during orthogonal turning is proposed. This model, which is based on the energy approach combined with the microfriction and the plastic deformation of the material, takes into account the tool geometry, the properties of the worked material, the cutting conditions, and the chip segmentation. The model is validated using experimental results obtained during the orthogonal turning of 6061-T6 aluminum alloy, AISI 1018, AISI 4140 steels, and grey cast iron. A good agreement was found with experimental results. This model can help in designing strategies for reducing particle emission during machining processes, at the source.

Ultrasonic/Sonic Jackhammer

NASA Technical Reports Server (NTRS)

Bar-Cohen, Yoseph; Sherrit, Stewart; Herz, Jack

2005-01-01

An ultrasonic/sonic jackhammer (USJ) is the latest in a series of related devices. Each of these devices cuts into a brittle material by means of hammering and chiseling actions of a tool bit excited with a combination of ultrasonic and sonic vibrations. A small-scale prototype of the USJ has been demonstrated. A fully developed, full-scale version of the USJ would be used for cutting through concrete, rocks, hard asphalt, and other materials to which conventional pneumatic jackhammers are applied, but the USJ would offer several advantages over conventional pneumatic jackhammers.

Efficient production by laser materials processing integrated into metal cutting machines

NASA Astrophysics Data System (ADS)

Wiedmaier, M.; Meiners, E.; Dausinger, Friedrich; Huegel, Helmut

1994-09-01

Beam guidance of high power YAG-laser (cw, pulsed, Q-switched) with average powers up to 2000 W by flexible glass fibers facilitates the integration of the laser beam as an additional tool into metal cutting machines. Hence, technologies like laser cutting, joining, hardening, caving, structuring of surfaces and laser-marking can be applied directly inside machining centers in one setting, thereby reducing the flow of workpieces resulting in a lowering of costs and production time. Furthermore, materials with restricted machinability--especially hard materials like ceramics, hard metals or sintered alloys--can be shaped by laser-caving or laser assisted machining. Altogether, the flexibility of laser integrated machining centers is substantially increased or the efficiency of a production line is raised by time-savings or extended feasibilities with techniques like hardening, welding or caving.

Mathematical modelling and numerical simulation of forces in milling process

NASA Astrophysics Data System (ADS)

Turai, Bhanu Murthy; Satish, Cherukuvada; Prakash Marimuthu, K.

2018-04-01

Machining of the material by milling induces forces, which act on the work piece material, tool and which in turn act on the machining tool. The forces involved in milling process can be quantified, mathematical models help to predict these forces. A lot of research has been carried out in this area in the past few decades. The current research aims at developing a mathematical model to predict forces at different levels which arise machining of Aluminium6061 alloy. Finite element analysis was used to develop a FE model to predict the cutting forces. Simulation was done for varying cutting conditions. Different experiments was designed using Taguchi method. A L9 orthogonal array was designed and the output was measure for the different experiments. The same was used to develop the mathematical model.

Analytical and Empirical Modeling of Wear and Forces of CBN Tool in Hard Turning - A Review

NASA Astrophysics Data System (ADS)

Patel, Vallabh Dahyabhai; Gandhi, Anishkumar Hasmukhlal

2017-08-01

Machining of steel material having hardness above 45 HRC (Hardness-Rockwell C) is referred as a hard turning. There are numerous models which should be scrutinized and implemented to gain optimum performance of hard turning. Various models in hard turning by cubic boron nitride tool have been reviewed, in attempt to utilize appropriate empirical and analytical models. Validation of steady state flank and crater wear model, Usui's wear model, forces due to oblique cutting theory, extended Lee and Shaffer's force model, chip formation and progressive flank wear have been depicted in this review paper. Effort has been made to understand the relationship between tool wear and tool force based on the different cutting conditions and tool geometries so that appropriate model can be used according to user requirement in hard turning.

Diamond Smoothing Tools

NASA Technical Reports Server (NTRS)

Voronov, Oleg

2007-01-01

Diamond smoothing tools have been proposed for use in conjunction with diamond cutting tools that are used in many finish-machining operations. Diamond machining (including finishing) is often used, for example, in fabrication of precise metal mirrors. A diamond smoothing tool according to the proposal would have a smooth spherical surface. For a given finish machining operation, the smoothing tool would be mounted next to the cutting tool. The smoothing tool would slide on the machined surface left behind by the cutting tool, plastically deforming the surface material and thereby reducing the roughness of the surface, closing microcracks and otherwise generally reducing or eliminating microscopic surface and subsurface defects, and increasing the microhardness of the surface layer. It has been estimated that if smoothing tools of this type were used in conjunction with cutting tools on sufficiently precise lathes, it would be possible to reduce the roughness of machined surfaces to as little as 3 nm. A tool according to the proposal would consist of a smoothing insert in a metal holder. The smoothing insert would be made from a diamond/metal functionally graded composite rod preform, which, in turn, would be made by sintering together a bulk single-crystal or polycrystalline diamond, a diamond powder, and a metallic alloy at high pressure. To form the spherical smoothing tip, the diamond end of the preform would be subjected to flat grinding, conical grinding, spherical grinding using diamond wheels, and finally spherical polishing and/or buffing using diamond powders. If the diamond were a single crystal, then it would be crystallographically oriented, relative to the machining motion, to minimize its wear and maximize its hardness. Spherically polished diamonds could also be useful for purposes other than smoothing in finish machining: They would likely also be suitable for use as heat-resistant, wear-resistant, unlubricated sliding-fit bearing inserts.

Slice-push, formation of grooves and the scale effect in cutting.

PubMed

Atkins, A G

2016-06-06

Three separate aspects of cutting are investigated which complement other papers on the mechanics of separation processes presented at this interdisciplinary Theo Murphy meeting. They apply in all types of cutting whether blades are sharp or blunt, and whether the material being cut is 'hard, stiff and strong' or 'soft, compliant and weak'. The first topic discusses why it is easier to cut when there is motion along (parallel to) the blade as well motion across (perpendicular to) the cutting edge, and the analysis is applied to optimization of blade geometries to produce minimum cutting forces and hence minimum damage to cut surfaces. The second topic concerns cutting with more than one edge with particular application to the formation of grooves in surfaces by hard pointed tools. The mechanics are investigated and applied to the topic of abrasive wear by hard particles. Traditional analyses say that abrasive wear resistance increases monotonically with the hardness of the workpiece, but we show that the fracture toughness of the surface material is also important, and that behaviour is determined by the toughness-to-hardness ratio rather than hardness alone. Scaling forms the third subject. As cutting is a branch of elasto-plastic fracture mechanics, cube-square energy scaling applies in which the important length scale is (ER/k (2)), where E is Young's modulus, R is the fracture toughness and k is the shear yield strength. Whether, in cutting, material is removed as ductile ribbons, as semi-ductile discontinuous chips, or by brittle 'knocking lumps out' is shown to depend on the depth of cut relative to this characteristic length parameter. Scaling in biology is called allometry and its relationship with engineering scaling is discussed. Some speculative predictions are made in relation to the action of teeth on food.

Microbiopsy/precision cutting devices

DOEpatents

Krulevitch, Peter A.; Lee, Abraham P.; Northrup, M. Allen; Benett, William J.

1999-01-01

Devices for performing tissue biopsy on a small scale (microbiopsy). By reducing the size of the biopsy tool and removing only a small amount of tissue or other material in a minimally invasive manner, the risks, costs, injury and patient discomfort associated with traditional biopsy procedures can be reduced. By using micromachining and precision machining capabilities, it is possible to fabricate small biopsy/cutting devices from silicon. These devices can be used in one of four ways 1) intravascularly, 2) extravascularly, 3) by vessel puncture, and 4) externally. Additionally, the devices may be used in precision surgical cutting.

An evaluation of dental operative simulation materials.

PubMed

He, Li-Hong; Foster Page, Lyndie; Purton, David

2012-01-01

The study was to evaluate the performance of different materials used in dental operative simulation and compare them with those of natural teeth. Three typical phantom teeth materials were compared with extracted permanent teeth by a nanoindentation system and evaluated by students and registered dentists on the drilling sensation of the materials. Moreover, the tool life (machinability) of new cylindrical diamond burs on cutting the sample materials was tested and the burs were observed. Although student and dentist evaluations were scattered and inconclusive, it was found that elastic modulus (E) and hardness (H) were not the main factors in determining the drilling sensation of the materials. The sensation of drilling is a reflection of cutting force and power consumption.An ideal material for dental simulation should be able to generate similar drilling resistance to that of natural tooth, which is the machinability of the material.

Surface structuring of boron doped CVD diamond by micro electrical discharge machining

NASA Astrophysics Data System (ADS)

Schubert, A.; Berger, T.; Martin, A.; Hackert-Oschätzchen, M.; Treffkorn, N.; Kühn, R.

2018-05-01

Boron doped diamond materials, which are generated by Chemical Vapor Deposition (CVD), offer a great potential for the application on highly stressed tools, e. g. in cutting or forming processes. As a result of the CVD process rough surfaces arise, which require a finishing treatment in particular for the application in forming tools. Cutting techniques such as milling and grinding are hardly applicable for the finish machining because of the high strength of diamond. Due to its process principle of ablating material by melting and evaporating, Electrical Discharge Machining (EDM) is independent of hardness, brittleness or toughness of the workpiece material. EDM is a suitable technology for machining and structuring CVD diamond, since boron doped CVD diamond is electrically conductive. In this study the ablation characteristics of boron doped CVD diamond by micro electrical discharge machining are investigated. Experiments were carried out to investigate the influence of different process parameters on the machining result. The impact of tool-polarity, voltage and discharge energy on the resulting erosion geometry and the tool wear was analyzed. A variation in path overlapping during the erosion of planar areas leads to different microstructures. The results show that micro EDM is a suitable technology for finishing of boron doped CVD diamond.

Performance evaluation of Titanium nitride coated tool in turning of mild steel

NASA Astrophysics Data System (ADS)

Srinivas, B.; Pramod Kumar, G.; Cheepu, Muralimohan; Jagadeesh, N.; kumar, K. Ravi; Haribabu, S.

2018-03-01

The growth in demand for bio-gradable materials is opened as a venue for using vegetable oils, coconut oils etc., as alternate to the conventional coolants for machining operations. At present in manufacturing industries the demand for surface quality is increasing rapidly along with dimensional accuracy and geometric tolerances. The present study is influence of cutting parameters on the surface roughness during the turning of mild steel with TiN coated carbide tool using groundnut oil and soluble oil as coolants. The results showed vegetable gave closer surface finish compares with soluble oil. Cutting parameters has been optimized with Taguchi technique. In this paper, the main objective is to optimize the cutting parameters and reduce surface roughness analogous to increase the tool life by apply the coating on the carbide inserts. The cost of the coating is more, but economically efficient than changing the tools frequently. The plots were generated and analysed to find the relationship between them which are confirmed by performing a comparison study between the predicted results and theoretical results.

Development and testing of an active boring bar for increased chatter immunity

DOE Office of Scientific and Technical Information (OSTI.GOV)

Redmond, J.; Barney, P.

Recent advances in smart materials have renewed interest in the development of improved manufacturing processes featuring sensing, processing, and active control. In particular, vibration suppression in metal cutting has received much attention because of its potential for enhancing part quality while reducing the time and cost of production. Although active tool clamps have been recently demonstrated, they are often accompanied by interfacing issues that limit their applicability to specific machines. Under the auspices of the Laboratory Directed Research and Development program, the project titled {open_quotes}Smart Cutting Tools for Precision Manufacturing{close_quotes} developed an alternative approach to active vibration control in machining.more » Using the boring process as a vehicle for exploration, a commercially available tool was modified to incorporate PZT stack actuators for active suppression of its bending modes. Since the modified tool requires no specialized mounting hardware, it can be readily mounted on many machines. Cutting tests conducted on a horizontal lathe fitted with a hardened steel workpiece verify that the actively damped boring bar yields significant vibration reduction and improved surface finishes as compared to an unmodified tool.« less

Method and apparatus for suppressing regenerative instability and related chatter in machine tools

DOEpatents

Segalman, Daniel J.; Redmond, James M.

2001-01-01

Methods of and apparatuses for mitigating chatter vibrations in machine tools or components thereof. Chatter therein is suppressed by periodically or continuously varying the stiffness of the cutting tool (or some component of the cutting tool), and hence the resonant frequency of the cutting tool (or some component thereof). The varying of resonant frequency of the cutting tool can be accomplished by modulating the stiffness of the cutting tool, the cutting tool holder, or any other component of the support for the cutting tool. By periodically altering the impedance of the cutting tool assembly, chatter is mitigated. In one embodiment, a cyclic electric (or magnetic) field is applied to the spindle quill which contains an electro-rheological (or magneto-rheological) fluid. The variable yield stress in the fluid affects the coupling of the spindle to the machine tool structure, changing the natural frequency of oscillation. Altering the modal characteristics in this fashion disrupts the modulation of current tool vibrations with previous tool vibrations recorded on the workpiece surface.

Method and apparatus for suppressing regenerative instability and related chatter in machine tools

DOEpatents

Segalman, Daniel J.; Redmond, James M.

1999-01-01

Methods of and apparatuses for mitigating chatter vibrations in machine tools or components thereof. Chatter therein is suppressed by periodically or continuously varying the stiffness of the cutting tool (or some component of the cutting tool), and hence the resonant frequency of the cutting tool (or some component thereof). The varying of resonant frequency of the cutting tool can be accomplished by modulating the stiffness of the cutting tool, the cutting tool holder, or any other component of the support for the cutting tool. By periodically altering the impedance of the cutting tool assembly, chatter is mitigated. In one embodiment, a cyclic electric (or magnetic) field is applied to the spindle quill which contains an electro-rheological (or magneto-rheological) fluid. The variable yield stress in the fluid affects the coupling of the spindle to the machine tool structure, changing the natural frequency of oscillation. Altering the modal characteristics in this fashion disrupts the modulation of current tool vibrations with previous tool vibrations recorded on the workpiece surface.

Adiabatic shear mechanisms for the hard cutting process

NASA Astrophysics Data System (ADS)

Yue, Caixu; Wang, Bo; Liu, Xianli; Feng, Huize; Cai, Chunbin

2015-05-01

The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride (PCBN) tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.

Introduction to Welding. Instructor Edition. Introduction to Construction Series.

ERIC Educational Resources Information Center

Oklahoma State Dept. of Vocational and Technical Education, Stillwater. Curriculum and Instructional Materials Center.

This document contains the materials necessary to teach four instructional units on welding that are designed to prepare learners for entry-level employment. The following instructional units are presented: (1) welding materials; (2) welding tools; (3) welding layout and basic skills; and (4) oxyacetylene cutting. The document begins with a copy…

Research of a smart cutting tool based on MEMS strain gauge

NASA Astrophysics Data System (ADS)

Zhao, Y.; Zhao, Y. L.; Shao, YW; Hu, T. J.; Zhang, Q.; Ge, X. H.

2018-03-01

Cutting force is an important factor that affects machining accuracy, cutting vibration and tool wear. Machining condition monitoring by cutting force measurement is a key technology for intelligent manufacture. Current cutting force sensors exist problems of large volume, complex structure and poor compatibility in practical application, for these problems, a smart cutting tool is proposed in this paper for cutting force measurement. Commercial MEMS (Micro-Electro-Mechanical System) strain gauges with high sensitivity and small size are adopted as transducing element of the smart tool, and a structure optimized cutting tool is fabricated for MEMS strain gauge bonding. Static calibration results show that the developed smart cutting tool is able to measure cutting forces in both X and Y directions, and the cross-interference error is within 3%. Its general accuracy is 3.35% and 3.27% in X and Y directions, and sensitivity is 0.1 mV/N, which is very suitable for measuring small cutting forces in high speed and precision machining. The smart cutting tool is portable and reliable for practical application in CNC machine tool.

Material Processing with High Power CO2-Lasers

NASA Astrophysics Data System (ADS)

Bakowsky, Lothar

1986-10-01

After a period of research and development lasertechnique now is regarded as an important instrument for flexible, economic and fully automatic manufacturing. Especially cutting of flat metal sheets with high power C02-lasers and CNC controlled two or three axes handling systems is a wide spread. application. Three dimensional laser cutting, laser-welding and -heat treatment are just at the be ginning of industrial use in production lines. The main. advantages of laser technology. are - high. accuracy - high, processing velocity - law thermal distortion. - no tool abrasion. The market for laser material processing systems had 1985 a volume of 300 Mio S with growth rates between, 20 % and 30 %. The topic of this lecture are hiTrh. power CO2-lasers. Besides this systems two others are used as machining tools, Nd-YAG- and Eximer lasers. All applications of high. power CO2-lasers to industrial material processing show that high processing velocity and quality are only guaranteed in case of a stable intensity. profile on the workpiece. This is only achieved by laser systems without any power and mode fluctuations and by handling systems of high accuracy. Two applications in the automotive industry are described, below as examples for laser cutting and laser welding of special cylindrical motor parts.

Adhesive bonded structural repair. II - Surface preparation procedures, tools, equipment and facilities

NASA Astrophysics Data System (ADS)

Wegman, Raymond F.; Tullos, Thomas R.

1993-10-01

A development status report is presented on the surface preparation procedures, tools, equipment, and facilities used in adhesively-bonded repair of aerospace and similar high-performance structures. These methods extend to both metallic and polymeric surfaces. Attention is given to the phos-anodize containment system, paint removal processes, tools for cutting composite prepreg and fabric materials, autoclaves, curing ovens, vacuum bagging, and controlled atmospheres.

Swept Mechanism of Micro-Milling Tool Geometry Effect on Machined Oxygen Free High Conductivity Copper (OFHC) Surface Roughness

PubMed Central

Shi, Zhenyu; Liu, Zhanqiang; Li, Yuchao; Qiao, Yang

2017-01-01

Cutting tool geometry should be very much considered in micro-cutting because it has a significant effect on the topography and accuracy of the machined surface, particularly considering the uncut chip thickness is comparable to the cutting edge radius. The objective of this paper was to clarify the influence of the mechanism of the cutting tool geometry on the surface topography in the micro-milling process. Four different cutting tools including two two-fluted end milling tools with different helix angles of 15° and 30° cutting tools, as well as two three-fluted end milling tools with different helix angles of 15° and 30° were investigated by combining theoretical modeling analysis with experimental research. The tool geometry was mathematically modeled through coordinate translation and transformation to make all three cutting edges at the cutting tool tip into the same coordinate system. Swept mechanisms, minimum uncut chip thickness, and cutting tool run-out were considered on modeling surface roughness parameters (the height of surface roughness Rz and average surface roughness Ra) based on the established mathematical model. A set of cutting experiments was carried out using four different shaped cutting tools. It was found that the sweeping volume of the cutting tool increases with the decrease of both the cutting tool helix angle and the flute number. Great coarse machined surface roughness and more non-uniform surface topography are generated when the sweeping volume increases. The outcome of this research should bring about new methodologies for micro-end milling tool design and manufacturing. The machined surface roughness can be improved by appropriately selecting the tool geometrical parameters. PMID:28772479

Influence of water-miscible cutting fluid on tool wear behavior of various coated high-speed steel tools in hobbing

NASA Astrophysics Data System (ADS)

Sato, Yuta; Matsuoka, Hironori; Kubo, Akio; Ono, Hajime; Ryu, Takahiro; Qiu, Hua; Nakae, Takashi; Shuto, Shuichi; Watanabe, Suguru; Anan, Ruito

2017-04-01

This paper deals with the influence of water-miscible cutting fluid on tool life (flank wear) compared with that with dry cutting and water-insoluble cutting oil in hobbing. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were clarified. (1) The water-miscible cutting fluid used in the test prolongs the tool life for TiN-, TiAlN-, TiSiN- and AlCrSiN-coated tools in comparison with that obtained by dry cutting and water-insoluble cutting oil. (2) It was presumed that the tool wear decreases and the tool life is improved by the lubrication effect of the synthetic lubrication additive, mineral oil and sulfuric EP additive contained in the water-miscible cutting fluid, and also by the cooling effect.

Diamond tool wear detection method using cutting force and its power spectrum analysis in ultra-precision fly cutting

NASA Astrophysics Data System (ADS)

Zhang, G. Q.; To, S.

2014-08-01

Cutting force and its power spectrum analysis was thought to be an effective method monitoring tool wear in many cutting processes and a significant body of research has been conducted on this research area. However, relative little similar research was found in ultra-precision fly cutting. In this paper, a group of experiments were carried out to investigate the cutting forces and its power spectrum characteristics under different tool wear stages. Result reveals that the cutting force increases with the progress of tool wear. The cutting force signals under different tool wear stages were analyzed using power spectrum analysis. The analysis indicates that a characteristic frequency does exist in the power spectrum of the cutting force, whose power spectral density increases with the increasing of tool wear level, this characteristic frequency could be adopted to monitor diamond tool wear in ultra-precision fly cutting.

Pin on disk against ball on disk for the evaluation of wear improvement on cryo-treated metal cutting shears

NASA Astrophysics Data System (ADS)

Jimbert, P.; Iturrondobeitia, M.; Ibarretxe, J.; Fernandez-Martinez, R.

2015-03-01

When talking about trybology, the election of the laboratory experiment type is a common problem of discussion. Laboratory wear methods are not designed to exactly reproduce the real working conditions of the analyzed part itself but serve to engineers and researcher to extrapolate the laboratory results to the real application. In order to shed some light on this issue, two wear tests have been analyzed following an ASTM standard and using the same experimental parameters and testing pair-materials in order to be able to make a comparison: Pin-on-Disk (PoD) against Ball-on-Disk (BoD). Three different tool steel have been analyzed in this study, AISI D2, AISI A8 and AISI H13, used to produce metal cutting shears. Metal on metal dry sliding tests were designed in order to reproduce the tool working conditions. These three materials were cryogenically treated and compared against no cryogenically treated ones to measure the improvement on their wear resistance due to cryogenic treatment. Finally, the wear rates obtained with both laboratory tests were compared against some real production metal cutting tools wear data. Results revealed an improvement of the wear resistance for cryo-treated samples of around 20% with the BoD test and around 6% with the PoD test. Real production tools wear was calculated for one of the tool steels and for two different applications. The improvement was approximately the one revealed by the BoD test. So, for the studied case, the BoD laboratory test gives more realistic prediction of real tool life improvement due to the cryogenic treatment.

Usewear studies of flint tools with microPIXE and microRBS

NASA Astrophysics Data System (ADS)

Christensen, Marianne; Grime, Geoff; Menu, Michel; Walter, Philippe

1993-05-01

The use of ancient stone tools leaves a polish (usewear) on the cutting edge which can be studied to determine the material the tool had worked during its use. The film is formed by high pressure intrusion of the worked material into the microcavities of the chipped flint surface and so the film can also be analysed directly to determine the nature of the worked material. This paper describes the analysis of experimental flint tools which had worked bone and ivory using microbeam PIXE and RBS. It is found that PIXE used simultaneously with RBS allows the thickness and composition of the film to be determined and ivory distinguished from bone while RBS mapping allows the three-dimensional structure of the film to be determined.

Impact resistance of materials for guards on cutting machine tools--requirements in future European safety standards.

PubMed

Mewes, D; Trapp, R P

2000-01-01

Guards on machine tools are meant to protect operators from injuries caused by tools, workpieces, and fragments hurled out of the machine's working zone. This article presents the impact resistance requirements, which guards according to European safety standards for machine tools must satisfy. Based upon these standards the impact resistance of different guard materials was determined using cylindrical steel projectiles. Polycarbonate proves to be a suitable material for vision panels because of its high energy absorption capacity. The impact resistance of 8-mm thick polycarbonate is roughly equal to that of a 3-mm thick steel sheet Fe P01. The limited ageing stability, however, makes it necessary to protect polycarbonate against cooling lubricants by means of additional panes on both sides.

Experimental Investigation on Cutting Characteristics in Nanometric Plunge-Cutting of BK7 and Fused Silica Glasses

PubMed Central

An, Qinglong; Ming, Weiwei; Chen, Ming

2015-01-01

Ductile cutting are most widely used in fabricating high-quality optical glass components to achieve crack-free surfaces. For ultra-precision machining of brittle glass materials, critical undeformed chip thickness (CUCT) commonly plays a pivotal role in determining the transition point from ductile cutting to brittle cutting. In this research, cutting characteristics in nanometric cutting of BK7 and fused silica glasses, including machined surface morphology, surface roughness, cutting force and specific cutting energy, were investigated with nanometric plunge-cutting experiments. The same cutting speed of 300 mm/min was used in the experiments with single-crystal diamond tool. CUCT was determined according to the mentioned cutting characteristics. The results revealed that 320 nm was found as the CUCT in BK7 cutting and 50 nm was determined as the size effect of undeformed chip thickness. A high-quality machined surface could be obtained with the undeformed chip thickness between 50 and 320 nm at ductile cutting stage. Moreover, no CUCT was identified in fused silica cutting with the current cutting conditions, and brittle-fracture mechanism was confirmed as the predominant chip-separation mode throughout the nanometric cutting operation. PMID:28788010

Experimental Investigation on Cutting Characteristics in Nanometric Plunge-Cutting of BK7 and Fused Silica Glasses.

PubMed

An, Qinglong; Ming, Weiwei; Chen, Ming

2015-03-27

Ductile cutting are most widely used in fabricating high-quality optical glass components to achieve crack-free surfaces. For ultra-precision machining of brittle glass materials, critical undeformed chip thickness (CUCT) commonly plays a pivotal role in determining the transition point from ductile cutting to brittle cutting. In this research, cutting characteristics in nanometric cutting of BK7 and fused silica glasses, including machined surface morphology, surface roughness, cutting force and specific cutting energy, were investigated with nanometric plunge-cutting experiments. The same cutting speed of 300 mm/min was used in the experiments with single-crystal diamond tool. CUCT was determined according to the mentioned cutting characteristics. The results revealed that 320 nm was found as the CUCT in BK7 cutting and 50 nm was determined as the size effect of undeformed chip thickness. A high-quality machined surface could be obtained with the undeformed chip thickness between 50 and 320 nm at ductile cutting stage. Moreover, no CUCT was identified in fused silica cutting with the current cutting conditions, and brittle-fracture mechanism was confirmed as the predominant chip-separation mode throughout the nanometric cutting operation.

Quantifying the Mechanical Properties of Materials and the Process of Elastic-Plastic Deformation under External Stress on Material

PubMed Central

Valíček, Jan; Harničárová, Marta; Öchsner, Andreas; Hutyrová, Zuzana; Kušnerová, Milena; Tozan, Hakan; Michenka, Vít; Šepelák, Vladimír; Mitaľ, Dušan; Zajac, Jozef

2015-01-01

The paper solves the problem of the nonexistence of a new method for calculation of dynamics of stress-deformation states of deformation tool-material systems including the construction of stress-strain diagrams. The presented solution focuses on explaining the mechanical behavior of materials after cutting by abrasive waterjet technology (AWJ), especially from the point of view of generated surface topography. AWJ is a flexible tool accurately responding to the mechanical resistance of the material according to the accurately determined shape and roughness of machined surfaces. From the surface topography, it is possible to resolve the transition from ideally elastic to quasi-elastic and plastic stress-strain states. For detecting the surface structure, an optical profilometer was used. Based on the analysis of experimental measurements and the results of analytical studies, a mathematical-physical model was created and an exact method of acquiring the equivalents of mechanical parameters from the topography of surfaces generated by abrasive waterjet cutting and external stress in general was determined. The results of the new approach to the construction of stress-strain diagrams are presented. The calculated values agreed very well with those obtained by a certified laboratory VÚHŽ. PMID:28793645

Quantifying the Mechanical Properties of Materials and the Process of Elastic-Plastic Deformation under External Stress on Material.

PubMed

Valíček, Jan; Harničárová, Marta; Öchsner, Andreas; Hutyrová, Zuzana; Kušnerová, Milena; Tozan, Hakan; Michenka, Vít; Šepelák, Vladimír; Mitaľ, Dušan; Zajac, Jozef

2015-11-03

The paper solves the problem of the nonexistence of a new method for calculation of dynamics of stress-deformation states of deformation tool-material systems including the construction of stress-strain diagrams. The presented solution focuses on explaining the mechanical behavior of materials after cutting by abrasive waterjet technology (AWJ), especially from the point of view of generated surface topography. AWJ is a flexible tool accurately responding to the mechanical resistance of the material according to the accurately determined shape and roughness of machined surfaces. From the surface topography, it is possible to resolve the transition from ideally elastic to quasi-elastic and plastic stress-strain states. For detecting the surface structure, an optical profilometer was used. Based on the analysis of experimental measurements and the results of analytical studies, a mathematical-physical model was created and an exact method of acquiring the equivalents of mechanical parameters from the topography of surfaces generated by abrasive waterjet cutting and external stress in general was determined. The results of the new approach to the construction of stress-strain diagrams are presented. The calculated values agreed very well with those obtained by a certified laboratory VÚHŽ.

Microbiopsy/precision cutting devices

DOEpatents

Krulevitch, P.A.; Lee, A.P.; Northrup, M.A.; Benett, W.J.

1999-07-27

Devices are disclosed for performing tissue biopsy on a small scale (microbiopsy). By reducing the size of the biopsy tool and removing only a small amount of tissue or other material in a minimally invasive manner, the risks, costs, injury and patient discomfort associated with traditional biopsy procedures can be reduced. By using micromachining and precision machining capabilities, it is possible to fabricate small biopsy/cutting devices from silicon. These devices can be used in one of four ways (1) intravascularly, (2) extravascularly, (3) by vessel puncture, and (4) externally. Additionally, the devices may be used in precision surgical cutting. 6 figs.

Ultrasonic-impact grinder system

DOEpatents

Calkins, N.C.

1982-09-30

The disclosure relates to an ultrasonic impact grinding apparatus utilizing a counterweight to set an unloaded friction free condition. An added weight is used to optimize feed rate in accordance with the material to be cut, tool size and the like.

A probabilistic-based approach to monitoring tool wear state and assessing its effect on workpiece quality in nickel-based alloys

NASA Astrophysics Data System (ADS)

Akhavan Niaki, Farbod

The objective of this research is first to investigate the applicability and advantage of statistical state estimation methods for predicting tool wear in machining nickel-based superalloys over deterministic methods, and second to study the effects of cutting tool wear on the quality of the part. Nickel-based superalloys are among those classes of materials that are known as hard-to-machine alloys. These materials exhibit a unique combination of maintaining their strength at high temperature and have high resistance to corrosion and creep. These unique characteristics make them an ideal candidate for harsh environments like combustion chambers of gas turbines. However, the same characteristics that make nickel-based alloys suitable for aggressive conditions introduce difficulties when machining them. High strength and low thermal conductivity accelerate the cutting tool wear and increase the possibility of the in-process tool breakage. A blunt tool nominally deteriorates the surface integrity and damages quality of the machined part by inducing high tensile residual stresses, generating micro-cracks, altering the microstructure or leaving a poor roughness profile behind. As a consequence in this case, the expensive superalloy would have to be scrapped. The current dominant solution for industry is to sacrifice the productivity rate by replacing the tool in the early stages of its life or to choose conservative cutting conditions in order to lower the wear rate and preserve workpiece quality. Thus, monitoring the state of the cutting tool and estimating its effects on part quality is a critical task for increasing productivity and profitability in machining superalloys. This work aims to first introduce a probabilistic-based framework for estimating tool wear in milling and turning of superalloys and second to study the detrimental effects of functional state of the cutting tool in terms of wear and wear rate on part quality. In the milling operation, the mechanisms of tool failure were first identified and, based on the rapid catastrophic failure of the tool, a Bayesian inference method (i.e., Markov Chain Monte Carlo, MCMC) was used for parameter calibration of tool wear using a power mechanistic model. The calibrated model was then used in the state space probabilistic framework of a Kalman filter to estimate the tool flank wear. Furthermore, an on-machine laser measuring system was utilized and fused into the Kalman filter to improve the estimation accuracy. In the turning operation the behavior of progressive wear was investigated as well. Due to the nonlinear nature of wear in turning, an extended Kalman filter was designed for tracking progressive wear, and the results of the probabilistic-based method were compared with a deterministic technique, where significant improvement (more than 60% increase in estimation accuracy) was achieved. To fulfill the second objective of this research in understanding the underlying effects of wear on part quality in cutting nickel-based superalloys, a comprehensive study on surface roughness, dimensional integrity and residual stress was conducted. The estimated results derived from a probabilistic filter were used for finding the proper correlations between wear, surface roughness and dimensional integrity, along with a finite element simulation for predicting the residual stress profile for sharp and worn cutting tool conditions. The output of this research provides the essential information on condition monitoring of the tool and its effects on product quality. The low-cost Hall effect sensor used in this work to capture spindle power in the context of the stochastic filter can effectively estimate tool wear in both milling and turning operations, while the estimated wear can be used to generate knowledge of the state of workpiece surface integrity. Therefore the true functionality and efficiency of the tool in superalloy machining can be evaluated without additional high-cost sensing.

Surface and microstructure modifications of Ti-6Al-4V titanium alloy cutting by a water jet/high power laser converging coupling

NASA Astrophysics Data System (ADS)

Weiss, Laurent; Tazibt, Abdel; Aillerie, Michel; Tidu, Albert

2018-01-01

The metallurgical evolution of the Ti-6Al-4V samples is analyzed after an appropriate cutting using a converging water jet/high power laser system. New surface microstructures are obtained on the cutting edge as a result of thermo-mechanical effects of such hybrid fluid-jet-laser tool on the targeted material. The laser beam allows to melt and the water-jet to cool down and to evacuate the material upstream according to a controlled cutting process. The experimental results have shown that a rutile layer can be generated on the surface near the cutting zone. The recorded metallurgical effect is attributed to the chemical reaction between water molecules and titanium, where the laser thermal energy brought onto the surface plays the role of reaction activator. The width of the oxidized zone was found proportional to the cutting speed. During the reaction, hydrogen gas H2 is formed and is absorbed by the metal. The hydrogen atoms trapped into the alloy change the metastable phase formation developing pure β circular grains as a skin at the kerf surface. This result is original so it would lead to innovative converging laser water jet process that could be used to increase the material properties especially for surface treatment, a key value of surface engineering and manufacturing chains.

Ultrasonic Polishing

NASA Technical Reports Server (NTRS)

Gilmore, Randy

1993-01-01

The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries.

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

PubMed Central

Rezende, Bruna Aparecida; Silveira, Michele L.; Vieira, Luciano M. G.; Abrão, Alexandre M.; de Faria, Paulo Eustáquio; Rubio, Juan C. Campos

2016-01-01

Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry. PMID:28773895

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material.

PubMed

Rezende, Bruna Aparecida; Silveira, Michele L; Vieira, Luciano M G; Abrão, Alexandre M; Faria, Paulo Eustáquio de; Rubio, Juan C Campos

2016-09-13

Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry.

Constraint Optimization Problem For The Cutting Of A Cobalt Chrome Refractory Material

NASA Astrophysics Data System (ADS)

Lebaal, Nadhir; Schlegel, Daniel; Folea, Milena

2011-05-01

This paper shows a complete approach to solve a given problem, from the experimentation to the optimization of different cutting parameters. In response to an industrial problem of slotting FSX 414, a Cobalt-based refractory material, we have implemented a design of experiment to determine the most influent parameters on the tool life, the surface roughness and the cutting forces. After theses trials, an optimization approach has been implemented to find the lowest manufacturing cost while respecting the roughness constraints and cutting force limitation constraints. The optimization approach is based on the Response Surface Method (RSM) using the Sequential Quadratic programming algorithm (SQP) for a constrained problem. To avoid a local optimum and to obtain an accurate solution at low cost, an efficient strategy, which allows improving the RSM accuracy in the vicinity of the global optimum, is presented. With these models and these trials, we could apply and compare our optimization methods in order to get the lowest cost for the best quality, i.e. a satisfying surface roughness and limited cutting forces.

Mechanisms and FEM Simulation of Chip Formation in Orthogonal Cutting In-Situ TiB₂/7050Al MMC.

PubMed

Xiong, Yifeng; Wang, Wenhu; Jiang, Ruisong; Lin, Kunyang; Shao, Mingwei

2018-04-15

The in-situ TiB₂/7050Al composite is a new kind of Al-based metal matrix composite (MMC) with super properties, such as low density, improved strength, and wear resistance. This paper, for a deep insight into its cutting performance, involves a study of the chip formation process and finite element simulation during orthogonal cutting in-situ TiB₂/7050Al MMC. With chips, material properties, cutting forces, and tool geometry parameters, the Johnson-Cook (J-C) constitutive equation of in-situ TiB₂/7050Al composite was established. Then, the cutting simulation model was established by applying the Abaqus-Explicit method, and the serrated chip, shear plane, strain rate, and temperature were analyzed. The experimental and simulation results showed that the obtained material's constitutive equation was of high reliability, and the saw-tooth chips occurred commonly under either low or high cutting speed and small or large feed rate. From result analysis, it was found that the mechanisms of chip formation included plastic deformation, adiabatic shear, shearing slip, and crack extension. In addition, it was found that the existence of small, hard particles reduced the ductility of the MMC and resulted in segmental chips.

Little Caney River Prehistory. 1979 Field Season,

DTIC Science & Technology

1981-01-01

spurred tool used graver for puncturing soft materials, incising bone or skins 4o-t 22 Cutting tool A purposefully modified flake tool with working edge...of two facial implements do occur. The debitage burins(Figure4j-k)madeonthickflakeblanks. includes whole or fragmentary flakes having Incising of...is also sand tempered and-pecked. The ground stone slab/abrader is and is simple stamped or linearly incised on ground-and-marred and is from 50 cm

Effect of Cutting Parameters on Thrust Force and Surface Roughness in Drilling of Al-2219/B4C/Gr Metal Matrix Composites

NASA Astrophysics Data System (ADS)

Ravindranath, V. M.; Basavarajappa, G. S. Shiva Shankar S.; Suresh, R.

2016-09-01

In aluminium matrix composites, reinforcement of hard ceramic particle present inside the matrix which causes tool wear, high cutting forces and poor surface finish during machining. This paper focuses on effect of cutting parameters on thrust force, surface roughness and burr height during drilling of MMCs. In the present work, discuss the influence of spindle speed and feed rate on drilling the pure base alloy (Al-2219), mono composite (Al- 2219+8% B4C) and hybrid composite (Al-2219+8%B4C+3%Gr). The composites were fabricated using liquid metallurgy route. The drilling experiments were conducted by CNC machine with TiN coated HSS tool, M42 (Cobalt grade) and carbide tools at various spindle speeds and feed rates. The thrust force, surface roughness and burr height of the drilled hole were investigated in mono composite and hybrid composite containing graphite particles, the experimental results show that the feed rate has more influence on thrust force and surface roughness. Lesser thrust force and discontinuous chips were produced during machining of hybrid composites when compared with mono and base alloy during drilling process. It is due to solid lubricant property of graphite which reduces the lesser thrust force, burr height and lower surface roughness. When machining with Carbide tool at low feed and high speeds good surface finish was obtained compared to other two types of cutting tool materials.

Modelling of tunnelling processes and rock cutting tool wear with the particle finite element method

NASA Astrophysics Data System (ADS)

Carbonell, Josep Maria; Oñate, Eugenio; Suárez, Benjamín

2013-09-01

Underground construction involves all sort of challenges in analysis, design, project and execution phases. The dimension of tunnels and their structural requirements are growing, and so safety and security demands do. New engineering tools are needed to perform a safer planning and design. This work presents the advances in the particle finite element method (PFEM) for the modelling and the analysis of tunneling processes including the wear of the cutting tools. The PFEM has its foundation on the Lagrangian description of the motion of a continuum built from a set of particles with known physical properties. The method uses a remeshing process combined with the alpha-shape technique to detect the contacting surfaces and a finite element method for the mechanical computations. A contact procedure has been developed for the PFEM which is combined with a constitutive model for predicting the excavation front and the wear of cutting tools. The material parameters govern the coupling of frictional contact and wear between the interacting domains at the excavation front. The PFEM allows predicting several parameters which are relevant for estimating the performance of a tunnelling boring machine such as wear in the cutting tools, the pressure distribution on the face of the boring machine and the vibrations produced in the machinery and the adjacent soil/rock. The final aim is to help in the design of the excavating tools and in the planning of the tunnelling operations. The applications presented show that the PFEM is a promising technique for the analysis of tunnelling problems.

Cutting tools and wear resistant articles and material for same

DOEpatents

Tien, Tseng-Ying; Huang, Zhen-Kun

2000-01-01

A ceramic having a relatively high proportion of an alpha prime SiAlON phase and exhibiting high hardness and toughness. In a particularly preferred embodiment, a cation of Gd is used as a modifying cation.

Microgravity

NASA Image and Video Library

1994-02-03

The objective of this facility is to investigate the potential of space grown semiconductor materials by the vapor transport technique and develop powdered metal and ceramic sintering techniques in microgravity. The materials processed or developed in the SEF have potential application for improving infrared detectors, nuclear particle detectors, photovoltaic cells, bearing cutting tools, electrical brushes and catalysts for chemical production. Flown on STS-60 Commercial Center: Consortium for Materials Development in Space - University of Alabama Huntsville (UAH)

Design and development of solid carbide step drill K34 for machining of CFRP and GFRP composite laminates

NASA Astrophysics Data System (ADS)

Rangaswamy, T.; Nagaraja, R.

2018-04-01

The Study focused on design and development of solid carbide step drill K34 to drill holes on composite materials such as Carbon Fiber Reinforced Plastic (CFRP) and Glass Fiber Reinforced Plastic (GFRP). The step drill K34 replaces step wise drilling of diameter 6.5mm and 9 mm holes that reduces the setup time, cutting speed, feed rate cost, delamination and increase the production rate. Several researchers have analyzed the effect of drilling process on various fiber reinforced plastic composites by carrying out using conventional tools and machinery. However, this process operation can lead to different kind of damages such as delamination, fiber pullout, and local cracks. To avoid the problems encountered at the time of drilling, suitable tool material and geometry is essential. This paper deals with the design and development of K34 Carbide step drill used to drill holes on CFRP and GFRP laminates. An Experimental study carried out to investigate the tool geometry, feed rate and cutting speed that avoids delamination and fiber breakage.

Chip morphology as a performance predictor during high speed end milling of soda lime glass

NASA Astrophysics Data System (ADS)

Bagum, M. N.; Konneh, M.; Abdullah, K. A.; Ali, M. Y.

2018-01-01

Soda lime glass has application in DNA arrays and lab on chip manufacturing. Although investigation revealed that machining of such brittle material is possible using ductile mode under controlled cutting parameters and tool geometry, it remains a challenging task. Furthermore, ability of ductile machining is usually assed through machined surface texture examination. Soda lime glass is a strain rate and temperature sensitive material. Hence, influence on attainment of ductile surface due to adiabatic heat generated during high speed end milling using uncoated tungsten carbide tool is investigated in this research. Experimental runs were designed using central composite design (CCD), taking spindle speed, feed rate and depth of cut as input variable and tool-chip contact point temperature (Ttc) and the surface roughness (Rt) as responses. Along with machined surface texture, Rt and chip morphology was examined to assess machinability of soda lime glass. The relation between Ttc and chip morphology was examined. Investigation showed that around glass transition temperature (Tg) ductile chip produced and subsequently clean and ductile final machined surface produced.

An investigation of chatter and tool wear when machining titanium

NASA Technical Reports Server (NTRS)

Sutherland, I. A.

1974-01-01

The low thermal conductivity of titanium, together with the low contact area between chip and tool and the unusually high chip velocities, gives rise to high tool tip temperatures and accelerated tool wear. Machining speeds have to be considerably reduced to avoid these high temperatures with a consequential loss of productivity. Restoring this lost productivity involves increasing other machining variables, such as feed and depth-of-cut, and can lead to another machining problem commonly known as chatter. This work is to acquaint users with these problems, to examine the variables that may be encountered when machining a material like titanium, and to advise the machine tool user on how to maximize the output from the machines and tooling available to him. Recommendations are made on ways of improving tolerances, reducing machine tool instability or chatter, and improving productivity. New tool materials, tool coatings, and coolants are reviewed and their relevance examined when machining titanium.

On the performances and wear of WC-diamond like carbon coated tools in drilling of CFRP/Titanium stacks

NASA Astrophysics Data System (ADS)

Boccarusso, L.; Durante, M.; Impero, F.; Minutolo, F. Memola Capece; Scherillo, F.; Squillace, A.

2016-10-01

The use of hybrid structures made of CFRP and titanium alloys is growing more and more in the last years in the aerospace industry due to the high strength to weight ratio. Because of their very different characteristics, the mechanical fastening represent the most effective joining technique for these materials. As a consequence, drilling process plays a key role in the assembly. The one shot drilling, i.e. the contemporary drilling of the stack of the two materials, seems to be the best option both in terms of time saving and assembly accuracy. Nevertheless, due to the considerable different machinability of fiber reinforced plastics and metallic materials, the one shot drilling is a critical process both for the holes quality and for the tools wear. This research was carried out to study the effectiveness of new generation tools in the drilling of CFRP/Titanium stacks. The tools are made of sintered grains of tungsten carbide (WC) in a binder of cobalt and coated with Diamond like carbon (DLC), and are characterized by a patented geometry; they mainly differ in parent WC grain size and binder percentage. Both the cutting forces and the wear phenomena were accurately investigated and the results were analyzed as a function of number of holes and their quality. The results show a clear increase of the cutting forces with the number of holes for all the used drilling tools. Moreover, abrasive wear phenomena that affect initially the tools coating layer were observed.

Effect of tool material on machinability of TiCp reinforced Al-1100 composite

NASA Astrophysics Data System (ADS)

Harishchandra; Kadadevaramath, R. S.; Anil, K. C.

2016-09-01

In present days MMC's are widely used in most of the industries, like automobiles, aerospace, minerals and marine industries, because of its high specific strength to weight ratio. There are many types of reinforcements are available, selection of reinforcement is depends on availability, cost and desired reinforcement properties. In our study Al-1100 is selected as a primary material and Titanium carbide particle (TiCp) of 44 pm size as reinforcement and synthesized by manual stir casting method, by varying the reinforcement percentage. K2DF6 salt was used as wetting agent in order to improve the wetting behaviour of the reinforcement and same was observed in optical micrographs. Further, prepared composite materials are subjected to machinability studies by using lathe tool dynamometer in order to evaluate the cutting force, surface roughness with respect to reinforcement percentage and tool material. From the results, it is observed that the hardness and surface roughness of a specimen increases with the increasing of reinforcement percentage and Hardness of the tool material respectively.

Effect of micro-scale texturing on the cutting tool performance

NASA Astrophysics Data System (ADS)

Vasumathy, D.; Meena, Anil

2018-05-01

The present study is mainly focused on the cutting performance of the micro-scale textured carbide tools while turning AISI 304 austenitic stainless steel under dry cutting environment. The texture on the rake face of the carbide tools was fabricated by laser machining. The cutting performance of the textured tools was further compared with conventional tools in terms of cutting forces, tool wear, machined surface quality and chip curl radius. SEM and EDS analyses have been also performed to better understand the tool surface characteristics. Results show that the grooves help in breaking the tool-chip contact leading to a lesser tool-chip contact area which results in reduced iron (Fe) adhesion to the tool.

Triphasic Tooling with Small Oriented Diamond Tip for Turning and Smoothing Lightweight Mirrors

NASA Technical Reports Server (NTRS)

Voronov, O. A.; Tompa, G. S.; Kear, B. H.; Veress, V.

2004-01-01

We are developing a new method for the growth of small diamond crystals at very high temperatures and pressures directly from a carbon melt. A prototype "Supercell" has been developed for this purpose. This system is capable of high rate crystal growth in relatively large working volumes. The resulting high quality diamond crystals will be incorporated into a triphasic diamond/titanium carbide/titanium composite tool, with an oriented diamond crystal at its tip. High pressure is needed to prevent degradation of diamond at high temperature, and to ensure the formation of a crack & composite structure. After grinding and polishing, the composite material will be joined to a steel holder, thus forming a diamond-tipped tool for turning and smoothing of a mirror surface. A properly oriented single-crystal diamond cuts and smoothes much better than a conventional polycrystalline diamond crystal. This is because the hardness depends on crystallographic orientation-the difference corresponds to 60-100 GPa on the Knoop scale. Our goal is to achieve surface roughness of about 1 nm, which will be accomplished by precision cutting and smoothing. The hardness of the functionally-graded diamond/titanium carbide/titanium composite tool varies from 100 GPa at its tip to 15 GPa at its base. Previous work has shown that the mass of machined material using an oriented-diamond tool is much larger than that for a standard diamond-metal composite tool.

Study on the separation effect of high-speed ultrasonic vibration cutting.

PubMed

Zhang, Xiangyu; Sui, He; Zhang, Deyuan; Jiang, Xinggang

2018-07-01

High-speed ultrasonic vibration cutting (HUVC) has been proven to be significantly effective when turning Ti-6Al-4V alloy in recent researches. Despite of breaking through the cutting speed restriction of the ultrasonic vibration cutting (UVC) method, HUVC can also achieve the reduction of cutting force and the improvements in surface quality and cutting efficiency in the high-speed machining field. These benefits all result from the separation effect that occurs during the HUVC process. Despite the fact that the influences of vibration and cutting parameters have been discussed in previous researches, the separation analysis of HUVC should be conducted in detail in real cutting situations, and the tool geometry parameters should also be considered. In this paper, three situations are investigated in details: (1) cutting without negative transient clearance angle and without tool wear, (2) cutting with negative transient clearance angle and without tool wear, and (3) cutting with tool wear. And then, complete separation state, partial separation state and continuous cutting state are deduced according to real cutting processes. All the analysis about the above situations demonstrate that the tool-workpiece separation will take place only if appropriate cutting parameters, vibration parameters, and tool geometry parameters are set up. The best separation effect was obtained with a low feedrate and a phase shift approaching 180 degrees. Moreover, flank face interference resulted from the negative transient clearance angle and tool wear contributes to an improved separation effect that makes the workpiece and tool separate even at zero phase shift. Finally, axial and radial transient cutting force are firstly obtained to verify the separation effect of HUVC, and the cutting chips are collected to weigh the influence of flank face interference. Copyright © 2018 Elsevier B.V. All rights reserved.

Investigating bone chip formation in craniotomy.

PubMed

Huiyu, He; Chengyong, Wang; Yue, Zhang; Yanbin, Zheng; Linlin, Xu; Guoneng, Xie; Danna, Zhao; Bin, Chen; Haoan, Chen

2017-10-01

In a craniotomy, the milling cutter is one of the most important cutting tools. The operating performance, tool durability and cutting damage to patients are influenced by the tool's sharpness, intensity and structure, whereas the cutting characteristics rely on interactions between the tool and the skull. In this study, an orthogonal cutting experiment during a craniotomy of fresh pig skulls was performed to investigate chip formation on the side cutting and face cutting of the skull using a high-speed camera. The cutting forces with different combinations of cutting parameters, such as the rake angle, clearance angle, depth of cut and cutting speed, were measured. The skull bone microstructure and cutting damage were observed by scanning electron microscope. Cutting models for different cutting approaches and various depths of cut were constructed and analyzed. The study demonstrated that the effects of shearing, tension and extrusion occur during chip formation. Various chip types, such as unit chips, splintering chips and continuous chips, were generated. Continuous pieces of chips, which are advisable for easy removal from the field of operation, were formed at greater depths of cut and tool rake angles greater than 10°. Cutting damage could be relieved with a faster recovery with clearance angles greater than 20°.

An ultra-precision tool nanoindentation instrument for replication of single point diamond tool cutting edges

NASA Astrophysics Data System (ADS)

Cai, Yindi; Chen, Yuan-Liu; Xu, Malu; Shimizu, Yuki; Ito, So; Matsukuma, Hiraku; Gao, Wei

2018-05-01

Precision replication of the diamond tool cutting edge is required for non-destructive tool metrology. This paper presents an ultra-precision tool nanoindentation instrument designed and constructed for replication of the cutting edge of a single point diamond tool onto a selected soft metal workpiece by precisely indenting the tool cutting edge into the workpiece surface. The instrument has the ability to control the indentation depth with a nanometric resolution, enabling the replication of tool cutting edges with high precision. The motion of the diamond tool along the indentation direction is controlled by the piezoelectric actuator of a fast tool servo (FTS). An integrated capacitive sensor of the FTS is employed to detect the displacement of the diamond tool. The soft metal workpiece is attached to an aluminum cantilever whose deflection is monitored by another capacitive sensor, referred to as an outside capacitive sensor. The indentation force and depth can be accurately evaluated from the diamond tool displacement, the cantilever deflection and the cantilever spring constant. Experiments were carried out by replicating the cutting edge of a single point diamond tool with a nose radius of 2.0 mm on a copper workpiece surface. The profile of the replicated tool cutting edge was measured using an atomic force microscope (AFM). The effectiveness of the instrument in precision replication of diamond tool cutting edges is well-verified by the experimental results.

A genetic algorithm used for solving one optimization problem

NASA Astrophysics Data System (ADS)

Shipacheva, E. N.; Petunin, A. A.; Berezin, I. M.

2017-12-01

A problem of minimizing the length of the blank run for a cutting tool during cutting of sheet materials into shaped blanks is discussed. This problem arises during the preparation of control programs for computerized numerical control (CNC) machines. A discrete model of the problem is analogous in setting to the generalized travelling salesman problem with limitations in the form of precursor conditions determined by the technological features of cutting. A certain variant of a genetic algorithm for solving this problem is described. The effect of the parameters of the developed algorithm on the solution result for the problem with limitations is investigated.

Machinability of IPS Empress 2 framework ceramic.

PubMed

Schmidt, C; Weigl, P

2000-01-01

Using ceramic materials for an automatic production of ceramic dentures by CAD/CAM is a challenge, because many technological, medical, and optical demands must be considered. The IPS Empress 2 framework ceramic meets most of them. This study shows the possibilities for machining this ceramic with economical parameters. The long life-time requirement for ceramic dentures requires a ductile machined surface to avoid the well-known subsurface damages of brittle materials caused by machining. Slow and rapid damage propagation begins at break outs and cracks, and limits life-time significantly. Therefore, ductile machined surfaces are an important demand for machine dental ceramics. The machining tests were performed with various parameters such as tool grain size and feed speed. Denture ceramics were machined by jig grinding on a 5-axis CNC milling machine (Maho HGF 500) with a high-speed spindle up to 120,000 rpm. The results of the wear test indicate low tool wear. With one tool, you can machine eight occlusal surfaces including roughing and finishing. One occlusal surface takes about 60 min machining time. Recommended parameters for roughing are middle diamond grain size (D107), cutting speed v(c) = 4.7 m/s, feed speed v(ft) = 1000 mm/min, depth of cut a(e) = 0.06 mm, width of contact a(p) = 0.8 mm, and for finishing ultra fine diamond grain size (D46), cutting speed v(c) = 4.7 m/s, feed speed v(ft) = 100 mm/min, depth of cut a(e) = 0.02 mm, width of contact a(p) = 0.8 mm. The results of the machining tests give a reference for using IPS Empress(R) 2 framework ceramic in CAD/CAM systems. Copyright 2000 John Wiley & Sons, Inc.

Nano Mechanical Machining Using AFM Probe

NASA Astrophysics Data System (ADS)

Mostofa, Md. Golam

Complex miniaturized components with high form accuracy will play key roles in the future development of many products, as they provide portability, disposability, lower material consumption in production, low power consumption during operation, lower sample requirements for testing, and higher heat transfer due to their very high surface-to-volume ratio. Given the high market demand for such micro and nano featured components, different manufacturing methods have been developed for their fabrication. Some of the common technologies in micro/nano fabrication are photolithography, electron beam lithography, X-ray lithography and other semiconductor processing techniques. Although these methods are capable of fabricating micro/nano structures with a resolution of less than a few nanometers, some of the shortcomings associated with these methods, such as high production costs for customized products, limited material choices, necessitate the development of other fabricating techniques. Micro/nano mechanical machining, such an atomic force microscope (AFM) probe based nano fabrication, has, therefore, been used to overcome some the major restrictions of the traditional processes. This technique removes material from the workpiece by engaging micro/nano size cutting tool (i.e. AFM probe) and is applicable on a wider range of materials compared to the photolithographic process. In spite of the unique benefits of nano mechanical machining, there are also some challenges with this technique, since the scale is reduced, such as size effects, burr formations, chip adhesions, fragility of tools and tool wear. Moreover, AFM based machining does not have any rotational movement, which makes fabrication of 3D features more difficult. Thus, vibration-assisted machining is introduced into AFM probe based nano mechanical machining to overcome the limitations associated with the conventional AFM probe based scratching method. Vibration-assisted machining reduced the cutting forces and burr formations through intermittent cutting. Combining the AFM probe based machining with vibration-assisted machining enhanced nano mechanical machining processes by improving the accuracy, productivity and surface finishes. In this study, several scratching tests are performed with a single crystal diamond AFM probe to investigate the cutting characteristics and model the ploughing cutting forces. Calibration of the probe for lateral force measurements, which is essential, is also extended through the force balance method. Furthermore, vibration-assisted machining system is developed and applied to fabricate different materials to overcome some of the limitations of the AFM probe based single point nano mechanical machining. The novelty of this study includes the application of vibration-assisted AFM probe based nano scale machining to fabricate micro/nano scale features, calibration of an AFM by considering different factors, and the investigation of the nano scale material removal process from a different perspective.

The effect of cutting conditions on power inputs when machining

NASA Astrophysics Data System (ADS)

Petrushin, S. I.; Gruby, S. V.; Nosirsoda, Sh C.

2016-08-01

Any technological process involving modification of material properties or product form necessitates consumption of a certain power amount. When developing new technologies one should take into account the benefits of their implementation vs. arising power inputs. It is revealed that procedures of edge cutting machining are the most energy-efficient amongst the present day forming procedures such as physical and technical methods including electrochemical, electroerosion, ultrasound, and laser processing, rapid prototyping technologies etc, such as physical and technical methods including electrochemical, electroerosion, ultrasound, and laser processing, rapid prototyping technologies etc. An expanded formula for calculation of power inputs is deduced, which takes into consideration the mode of cutting together with the tip radius, the form of the replaceable multifaceted insert and its wear. Having taken as an example cutting of graphite iron by the assembled cutting tools with replaceable multifaceted inserts the authors point at better power efficiency of high feeding cutting in comparison with high-speed cutting.

Cutting tool form compensation system and method

DOEpatents

Barkman, W.E.; Babelay, E.F. Jr.; Klages, E.J.

1993-10-19

A compensation system for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along a preprogrammed path during a machining operation utilizes a camera and a vision computer for gathering information at a preselected stage of a machining operation relating to the actual shape and size of the cutting edge of the cutting tool and for altering the preprogrammed path in accordance with detected variations between the actual size and shape of the cutting edge and an assumed size and shape of the cutting edge. The camera obtains an image of the cutting tool against a background so that the cutting tool and background possess contrasting light intensities, and the vision computer utilizes the contrasting light intensities of the image to locate points therein which correspond to points along the actual cutting edge. Following a series of computations involving the determining of a tool center from the points identified along the tool edge, the results of the computations are fed to the controller where the preprogrammed path is altered as aforedescribed. 9 figures.

Cutting tool form compensaton system and method

DOEpatents

Barkman, William E.; Babelay, Jr., Edwin F.; Klages, Edward J.

1993-01-01

A compensation system for a computer-controlled machining apparatus having a controller and including a cutting tool and a workpiece holder which are movable relative to one another along a preprogrammed path during a machining operation utilizes a camera and a vision computer for gathering information at a preselected stage of a machining operation relating to the actual shape and size of the cutting edge of the cutting tool and for altering the preprogrammed path in accordance with detected variations between the actual size and shape of the cutting edge and an assumed size and shape of the cutting edge. The camera obtains an image of the cutting tool against a background so that the cutting tool and background possess contrasting light intensities, and the vision computer utilizes the contrasting light intensities of the image to locate points therein which correspond to points along the actual cutting edge. Following a series of computations involving the determining of a tool center from the points identified along the tool edge, the results of the computations are fed to the controller where the preprogrammed path is altered as aforedescribed.

Adiabatic shear banding and scaling laws in chip formation with application to cutting of Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Molinari, A.; Soldani, X.; Miguélez, M. H.

2013-11-01

The phenomenon of adiabatic shear banding is analyzed theoretically in the context of metal cutting. The mechanisms of material weakening that are accounted for are (i) thermal softening and (ii) material failure related to a critical value of the accumulated plastic strain. Orthogonal cutting is viewed as a unique configuration where adiabatic shear bands can be experimentally produced under well controlled loading conditions by individually tuning the cutting speed, the feed (uncut chip thickness) and the tool geometry. The role of cutting conditions on adiabatic shear banding and chip serration is investigated by combining finite element calculations and analytical modeling. This leads to the characterization and classification of different regimes of shear banding and the determination of scaling laws which involve dimensionless parameters representative of thermal and inertia effects. The analysis gives new insights into the physical aspects of plastic flow instability in chip formation. The originality with respect to classical works on adiabatic shear banding stems from the various facets of cutting conditions that influence shear banding and from the specific role exercised by convective flow on the evolution of shear bands. Shear bands are generated at the tool tip and propagate towards the chip free surface. They grow within the chip formation region while being convected away by chip flow. It is shown that important changes in the mechanism of shear banding take place when the characteristic time of shear band propagation becomes equal to a characteristic convection time. Application to Ti-6Al-4V titanium are considered and theoretical predictions are compared to available experimental data in a wide range of cutting speeds and feeds. The fundamental knowledge developed in this work is thought to be useful not only for the understanding of metal cutting processes but also, by analogy, to similar problems where convective flow is also interfering with adiabatic shear banding as in impact mechanics and perforation processes. In that perspective, cutting speeds higher than those usually encountered in machining operations have been also explored.

JPRS Report, Science & Technology, USSR: Materials Science

DTIC Science & Technology

1988-01-08

ceramic product was found to have a high ratio of thickness-to-radial electromechanical coiipling coefficients. Dielectric permittivity and loss...equipment lacked just metal-cladding lubricants! The colossal capacities of metal-cutting equipment and tools, i.e. the foundation of all machine building

"Grinding" cavities in polyurethane foam

NASA Technical Reports Server (NTRS)

Brower, J. R.; Davey, R. E.; Dixon, W. F.; Robb, P. H.; Zebus, P. P.

1980-01-01

Grinding tool installed on conventional milling machine cuts precise cavities in foam blocks. Method is well suited for prototype or midsize production runs and can be adapted to computer control for mass production. Method saves time and materials compared to bonding or hot wire techniques.

Use of lasers in the furniture industry

NASA Astrophysics Data System (ADS)

Wieloch, Grzegorz; Pohl, Piotr

1995-03-01

One of the ways of using laser in industry is its usage in loss treatment of wood and composite wood products. In the furniture industry the above mentioned machining is used in such technological processes in which tool machining (sawing, molding) is not economical or even possible. These processes are mainly curvilinear cutting of layer materials like veneers, plywood, and face layers and thicker materials like particleboards, fiberboards, and lumber- core panels. Wide usage has also been achieved in heat treatment in wood for decoration. It can be calcinating designs, engraving them, blackening of parts of surfaces, or changing of anatomic characteristics of wood tissue. Nevertheless laser usage in recliner cutting seems at present causeless.

Tool feed influence on the machinability of CO(2) laser optics.

PubMed

Arnold, J B; Steger, P J; Saito, T T

1975-08-01

Influence of tool feed on reflectivity of diamond-machined surfaces was evaluated using materials (gold, silver, and copper) from which CO(2) laser optics are primarily produced. Fifteen specimens were machined by holding all machining parameters constant, except tool feed. Tool feed was allowed to vary by controlled amounts from one evaluation zone (or part) to another. Past experience has verified that the quality of a diamond-machined surface is not a function of the cutting velocity; therefore, this experiment was conducted on the basis that a variation in cutting velocity was not an influencing factor on the diamondturning process. Inspection results of the specimens indicated that tool feeds significantly higher than 5.1 micro/rev (200 microin./rev) produced detrimental effects on the machined surfaces. In some cases, at feeds as high as 13 microm/rev (500 microin./rev), visible scoring was evident. Those surfaces produced with tool feeds less than 5.1 microm/rev had little difference in reflectivity. Measurements indicat d that their reflectivity existed in a range from 96.7% to 99.3% at 10.6 microm.

Slide system for machine tools

DOEpatents

Douglass, S.S.; Green, W.L.

1980-06-12

The present invention relates to a machine tool which permits the machining of nonaxisymmetric surfaces on a workpiece while rotating the workpiece about a central axis of rotation. The machine tool comprises a conventional two-slide system (X-Y) with one of these slides being provided with a relatively short travel high-speed auxiliary slide which carries the material-removing tool. The auxiliary slide is synchronized with the spindle speed and the position of the other two slides and provides a high-speed reciprocating motion required for the displacement of the cutting tool for generating a nonaxisymmetric surface at a selected location on the workpiece.

Slide system for machine tools

DOEpatents

Douglass, Spivey S.; Green, Walter L.

1982-01-01

The present invention relates to a machine tool which permits the machining of nonaxisymmetric surfaces on a workpiece while rotating the workpiece about a central axis of rotation. The machine tool comprises a conventional two-slide system (X-Y) with one of these slides being provided with a relatively short travel high-speed auxiliary slide which carries the material-removing tool. The auxiliary slide is synchronized with the spindle speed and the position of the other two slides and provides a high-speed reciprocating motion required for the displacement of the cutting tool for generating a nonaxisymmetric surface at a selected location on the workpiece.

Prediction of 3D chip formation in the facing cutting with lathe machine using FEM

NASA Astrophysics Data System (ADS)

Prasetyo, Yudhi; Tauviqirrahman, Mohamad; Rusnaldy

2016-04-01

This paper presents the prediction of the chip formation at the machining process using a lathe machine in a more specific way focusing on facing cutting (face turning). The main purpose is to propose a new approach to predict the chip formation with the variation of the cutting directions i.e., the backward and forward direction. In addition, the interaction between stress analysis and chip formation on cutting process was also investigated. The simulations were conducted using three dimensional (3D) finite element method based on ABAQUS software with aluminum and high speed steel (HSS) as the workpiece and the tool materials, respectively. The simulation result showed that the chip resulted using a backward direction depicts a better formation than that using a conventional (forward) direction.

The Influence of High Pressure Thermal Behavior on Friction-induced material transfer During Dry Machining of Titanium

NASA Astrophysics Data System (ADS)

Abdel-Aal, H. A.; El Mansori, M.

2011-05-01

In this paper we study failure of coated carbide tools due to thermal loading. The study emphasizes the role assumed by the thermo-physical properties of the tool material in enhancing or preventing mass attrition of the cutting elements within the tool. It is shown that within a comprehensive view of the nature of conduction in the tool zone, thermal conduction is not solely affected by temperature. Rather it is a function of the so called thermodynamic forces. These are the stress, the strain, strain rate, rate of temperature rise, and the temperature gradient. Although that within such consideration description of thermal conduction is non-linear, it is beneficial to employ such a form because it facilitates a full mechanistic understanding of thermal activation of tool wear.

More About Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Oelgoetz, Peter A.; Davis, William M.

1996-01-01

Report describes modification and testing of proposed tool discussed in "Cutting Tool For Shaving Weld Beads" (MFS-30056). Modified version of commercial pneumatically driven rotary cutting tool removes such hard metals as nickel alloys, titanium, and stainless steels.

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

NASA Astrophysics Data System (ADS)

Cheng, Kai; Niu, Zhi-Chao; Wang, Robin C.; Rakowski, Richard; Bateman, Richard

2017-09-01

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 ultraprecision and micro manufacturing purposes. Implementation 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 techniques are presented focusing on: (a) plug-and-produce design principle and the associated smart control algorithms, (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) application exemplars on adaptive smart machining.

Excimer laser decoating of chromium titanium aluminium nitride to facilitate re-use of cutting tools

NASA Astrophysics Data System (ADS)

Sundar, M.; Whitehead, D.; Mativenga, P. T.; Li, L.; Cooke, K. E.

2009-11-01

This work reports on the technical feasibility and establishment of a process window for removing chromium titanium aluminium nitride (CrTiAlN) coating from steel substrates by laser irradiation. CrTiAlN coating has high hardness and oxidation resistance, with applications for use with cutting tools. The motivation for removing such coatings is to facilitate re-use of tooling by enabling regrinding or reshaping of a worn tool and hence promote sustainable material usage. In this work, laser decoating was performed using an excimer laser. The effect of laser fluence, number of pulses, frequency, scanning speed and laser beam overlap on the decoating performance was investigated in detail. The minimum threshold laser fluence for removing the CrTiAlN coating was lower than that of the steel substrate and this factor is beneficial in controlling the decoating process. Successful laser removal of CrTiAlN coating without noticeable damage to the steel substrate was demonstrated.

The machined surface of magnesium AZ31 after rotary turning at air cooling condition

NASA Astrophysics Data System (ADS)

Akhyar, G.; Purnomo, B.; Hamni, A.; Harun, S.; Burhanuddin, Y.

2018-04-01

Magnesium is a lightweight metal that is widely used as an alternative to iron and steel. Magnesium has been applied in the automotive industry to reduce the weight of a component, but the machining process has the disadvantage that magnesium is highly flammable because it has a low flash point. High temperature can cause the cutting tool wear and contributes to the quality of the surface roughness. The purpose of this study is to obtain the value of surface roughness and implement methods of rotary cutting tool and air cooling output vortex tube cooler to minimize the surface roughness values. Machining parameters that is turning using rotary cutting tool at speed the workpiece of (Vw) 50, 120, 160 m/min, cutting speed of rotary tool of (Vt) 25, 50, 75 m/min, feed rate of (f) 0.1, 0.15, 0.2 mm/rev, and depth of cut of 0.3 mm. Type of tool used is a carbide tool diameter of 16 mm and air cooling pressure of 6 bar. The results show the average value of the lowest surface roughness on the speed the workpiece of 80 m/min, cutting speed of rotary tool of 50 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.3 mm. While the average value of the highest surface roughness on the speed the workpiece of 160 m/min, cutting speed of rotary tool of 50 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.3 mm. The influence of machining parameters concluded the higher the speed of the workpiece the surface roughness value higher. Otherwise the higher cutting speed of rotary tool then the lower the surface roughness value. The observation on the surface of the rotary tool, it was found that no uniform tool wear which causes non-uniform surface roughness. The use of rotary cutting tool contributing to lower surface roughness values generated.

Research on operation mode of abrasive grain during grinding

NASA Astrophysics Data System (ADS)

Ivanova, T. N.; Dement’ev, V. B.; Nikitina, O. V.

2018-03-01

The processing of materials by cutting with an abrasive tool is carried out by means of thousands of grains bonded together as a single whole. The quality of the abrasive tool is defined by cutting properties of abrasive grains and depends on features of spreading the temperature field in time and in the abrasive grain volume. Grains are exposed to heating and cooling during work. It leads to undesired effects such as a decrease of durability of grain retention in the binder, hardness, intensification of diffusion and oxidation processes between the binder and the grain, the occurrence of considerable temperature stresses in the grain itself. The obtained equation which allows calculation of temperature field of grain for one rotation of grinding wheel shows that the temperature of the wheel depends on grinding modes and thermophysical properties of abrasive material. Thus, as the time of contact of grain with processed material increases, the temperature in the cutting area rises. As thermophysical properties increase, the temperature in cutting area decreases. Thermal working conditions are determined to be different from each other depending on contact time of the grain and the material. For example, in case of creep-feed grinding, the peak value of temperature is higher than during multistep grinding; the depth of expansion is greater. While the speed of the thermal process in creep-feed grinding is 2-3 times lower than in multistep grinding, the gradient reduces 3-4 times. The analysis of machining methods shows that creep-feed grinding ensures greater depth of grain heating, a smaller heating rate and a reduced velocity gradient. It causes a decrease of probable allotropic modifications and prevents from occurring of heat strokes - cracking of grains due to high temperature falls. Consequently, it is necessary to employ creep-feed grinding to increase the efficiency of abrasive tool employing. Three operation modes of grinding wheel including blunting, full self-sharpening, emergency wear and tear are determined as the result of the research on evaluation of cutting ability of grinding wheels. Recommendations for working capacity of grinding wheels in each operation mode and with a transition from one mode to another are given. As a result of the research, different dependencies were determined. They include dependencies, governing the extent of influence of granularity, difference in height and concentration of grains, geometry parameters of the detail to be machined and the grinding wheel on machining modes and the thickness of the layer cutoff by one grain. They have an influence on the grinding process.

Sustainable cooling method for machining titanium alloy

NASA Astrophysics Data System (ADS)

Boswell, B.; Islam, M. N.

2016-02-01

Hard to machine materials such as Titanium Alloy TI-6AI-4V Grade 5 are notoriously known to generate high temperatures and adverse reactions between the workpiece and the tool tip materials. These conditions all contribute to an increase in the wear mechanisms, reducing tool life. Titanium Alloy, for example always requires coolant to be used during machining. However, traditional flood cooling needs to be replaced due to environmental issues, and an alternative cooling method found that has minimum impact on the environment. For true sustainable cooling of the tool it is necessary to account for all energy used in the cooling process, including the energy involved in producing the coolant. Previous research has established that efficient cooling of the tool interface improves the tool life and cutting action. The objective of this research is to determine the most appropriate sustainable cooling method that can also reduce the rate of wear at the tool interface.

Engineering specification and system design for CAD/CAM of custom shoes: UMC project effort

NASA Technical Reports Server (NTRS)

Bao, Han P.

1990-01-01

Further experimentations were made to improve the design and fabrication techniques of the integrated sole. The sole design is shown to be related to the foot position requirements and the actual shape of the foot including presence of neurotropic ulcers or other infections. Factors for consideration were: heel pitch, balance line, and rigidity conditions of the foot. Machining considerations were also part of the design problem. Among these considerations, widths of each contour, tool motion, tool feed rate, depths of cut, and slopes of cut at the boundary were the key elements. The essential fabrication techniques evolved around the idea of machining a mold then, using quick-firm latex material, casting the sole through the mold. Two main mold materials were experimented with: plaster and wood. Plaster was very easy to machine and shape but could barely support the pressure in the hydraulic press required by the casting process. Wood was found to be quite effective in terms of relative cost, strength, and surface smoothness except for the problem of cutting against the fibers which could generate ragged surfaces. The programming efforts to convert the original dBase programs into C programs so that they could be executed on the SUN Computer at North Carolina State University are discussed.

Surface morphology study in high speed milling of soda lime glass

NASA Astrophysics Data System (ADS)

Konneh, Mohamed; Bagum, Mst. Nasima; Ali, Mohammad Yeakub; Amin, A. K. M. Nurul

2018-05-01

Soda lime glass has a wide range of applications in optical, bio-medical and semi-conductor industries. It is undeniably a challenging task to produce micro finish surface on an amorphous brittle solid like soda lime glass due to its low fracture toughness. In order to obtain such a finish surface, ductile machining has been exploited, as this usually cause's plastic flow which control crack propagation. At sub-micro scale cutting parameters, researchers achieved nano finish surface in micro milling operation using coated tool. However it is possible to enhance the rate of material removal (RMR) of soda lime glass at flexible cutting condition. High speed cutting at micro meter level, extend of thermal softening might be prominent than the strain gradient strengthening. The purpose of this study was to explore the effects of high cutting speed end milling parameters on the surface texture of soda lime glass using uncoated carbide tool. The spindle speed, depth of cut and feed rate were varied from 20,000 to 40,000 rpm, 10 to 30 mm/min and 30 to 50 µm respectively. Mathematical model of roughness has been developed using Response Surface Methodology (RSM). Experimental verification confirmed that surface roughness (Ra) 0.38 µm is possible to achieve at increased RMR, 4.71 mm3/min.

JPRS Report, Science & Technology, Europe.

DTIC Science & Technology

1991-06-10

ultrasound abrasion can be substituted for electroerosion with all nonconducting materials. The secret of ultrasound abrasion is a very hard tool (carved...in tungsten carbide takes the same time as with electroerosion . However, cutting a 1 mm hole will only take 50 minutes instead of 5 hours. "By

Modeling the milling tool wear by using an evolutionary SVM-based model from milling runs experimental data

NASA Astrophysics Data System (ADS)

Nieto, Paulino José García; García-Gonzalo, Esperanza; Vilán, José Antonio Vilán; Robleda, Abraham Segade

2015-12-01

The main aim of this research work is to build a new practical hybrid regression model to predict the milling tool wear in a regular cut as well as entry cut and exit cut of a milling tool. The model was based on Particle Swarm Optimization (PSO) in combination with support vector machines (SVMs). This optimization mechanism involved kernel parameter setting in the SVM training procedure, which significantly influences the regression accuracy. Bearing this in mind, a PSO-SVM-based model, which is based on the statistical learning theory, was successfully used here to predict the milling tool flank wear (output variable) as a function of the following input variables: the time duration of experiment, depth of cut, feed, type of material, etc. To accomplish the objective of this study, the experimental dataset represents experiments from runs on a milling machine under various operating conditions. In this way, data sampled by three different types of sensors (acoustic emission sensor, vibration sensor and current sensor) were acquired at several positions. A second aim is to determine the factors with the greatest bearing on the milling tool flank wear with a view to proposing milling machine's improvements. Firstly, this hybrid PSO-SVM-based regression model captures the main perception of statistical learning theory in order to obtain a good prediction of the dependence among the flank wear (output variable) and input variables (time, depth of cut, feed, etc.). Indeed, regression with optimal hyperparameters was performed and a determination coefficient of 0.95 was obtained. The agreement of this model with experimental data confirmed its good performance. Secondly, the main advantages of this PSO-SVM-based model are its capacity to produce a simple, easy-to-interpret model, its ability to estimate the contributions of the input variables, and its computational efficiency. Finally, the main conclusions of this study are exposed.

Double diameter boring tool

DOEpatents

Ashbaugh, Fred N.; Murry, Kenneth R.

1988-12-27

A boring tool and a method of operation are provided for boring two concentric holes of precision diameters and depths in a single operation. The boring tool includes an elongated tool body, a shank for attachment to a standard adjustable boring head which is used on a manual or numerical control milling machine and first and second diametrically opposed cutting edges formed for cutting in opposite directions. The diameter of the elongated tool body is substantially equal to the distance from the first cutting edge tip to the axis of rotation plus the distance from the second cutting edge tip to the axis of rotation. The axis of rotation of the tool is spaced from the tool centerline a distance substantially equal to one-half the distance from the second cutting edge tip to the axis of rotation minus one-half the distance from the first cutting edge tip to the axis of rotation. The method includes the step of inserting the boring tool into the boring head, adjusting the distance between the tool centerline and the tool axis of rotation as described above and boring the two concentric holes.

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites.

PubMed

Xiang, Junfeng; Pang, Siqin; Xie, Lijing; Gao, Feinong; Hu, Xin; Yi, Jie; Hu, Fang

2018-02-07

The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiC p /Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiC p /Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiC p /Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiC p /Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials.

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites

PubMed Central

Xiang, Junfeng; Pang, Siqin; Xie, Lijing; Gao, Feinong; Hu, Xin; Yi, Jie; Hu, Fang

2018-01-01

The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiCp/Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiCp/Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiCp/Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiCp/Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials. PMID:29414839

High-precision micro/nano-scale machining system

DOEpatents

Kapoor, Shiv G.; Bourne, Keith Allen; DeVor, Richard E.

2014-08-19

A high precision micro/nanoscale machining system. A multi-axis movement machine provides relative movement along multiple axes between a workpiece and a tool holder. A cutting tool is disposed on a flexible cantilever held by the tool holder, the tool holder being movable to provide at least two of the axes to set the angle and distance of the cutting tool relative to the workpiece. A feedback control system uses measurement of deflection of the cantilever during cutting to maintain a desired cantilever deflection and hence a desired load on the cutting tool.

Prosthetics & Orthotics Manufacturing Initiative (POMI)

DTIC Science & Technology

2012-12-21

the two materials. The rod was then put onto a lathe machine, allowing a thin sheet, with stripes of alternating materials, to be cut from the rod...tooling from. Mentis determined a method to use Aquacore, which involved machining blanks via CNC , followed by coating the mold to prevent resin...infusion into the mold. Mentis also attempted to use plaster combined with CNC machining, however, these molds did not survive the machining process

Drilling High Precision Holes in Ti6Al4V Using Rotary Ultrasonic Machining and Uncertainties Underlying Cutting Force, Tool Wear, and Production Inaccuracies.

PubMed

Chowdhury, M A K; Sharif Ullah, A M M; Anwar, Saqib

2017-09-12

Ti6Al4V alloys are difficult-to-cut materials that have extensive applications in the automotive and aerospace industry. A great deal of effort has been made to develop and improve the machining operations of Ti6Al4V alloys. This paper presents an experimental study that systematically analyzes the effects of the machining conditions (ultrasonic power, feed rate, spindle speed, and tool diameter) on the performance parameters (cutting force, tool wear, overcut error, and cylindricity error), while drilling high precision holes on the workpiece made of Ti6Al4V alloys using rotary ultrasonic machining (RUM). Numerical results were obtained by conducting experiments following the design of an experiment procedure. The effects of the machining conditions on each performance parameter have been determined by constructing a set of possibility distributions (i.e., trapezoidal fuzzy numbers) from the experimental data. A possibility distribution is a probability-distribution-neural representation of uncertainty, and is effective in quantifying the uncertainty underlying physical quantities when there is a limited number of data points which is the case here. Lastly, the optimal machining conditions have been identified using these possibility distributions.

Proposed algorithm to improve job shop production scheduling using ant colony optimization method

NASA Astrophysics Data System (ADS)

Pakpahan, Eka KA; Kristina, Sonna; Setiawan, Ari

2017-12-01

This paper deals with the determination of job shop production schedule on an automatic environment. On this particular environment, machines and material handling system are integrated and controlled by a computer center where schedule were created and then used to dictate the movement of parts and the operations at each machine. This setting is usually designed to have an unmanned production process for a specified interval time. We consider here parts with various operations requirement. Each operation requires specific cutting tools. These parts are to be scheduled on machines each having identical capability, meaning that each machine is equipped with a similar set of cutting tools therefore is capable of processing any operation. The availability of a particular machine to process a particular operation is determined by the remaining life time of its cutting tools. We proposed an algorithm based on the ant colony optimization method and embedded them on matlab software to generate production schedule which minimize the total processing time of the parts (makespan). We test the algorithm on data provided by real industry and the process shows a very short computation time. This contributes a lot to the flexibility and timelines targeted on an automatic environment.

High-Speed Edge Trimming of CFRP and Online Monitoring of Performance of Router Tools Using Acoustic Emission

PubMed Central

Prakash, Rangasamy; Krishnaraj, Vijayan; Zitoune, Redouane; Sheikh-Ahmad, Jamal

2016-01-01

Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields such as aerospace, automotive, and shipping industries due to their excellent mechanical properties that lead to enhanced functional performance. In this paper, an experimental study on edge trimming of CFRP was done with various cutting conditions and different geometry of tools such as helical-, fluted-, and burr-type tools. The investigation involves the measurement of cutting forces for the different machining conditions and its effect on the surface quality of the trimmed edges. The modern cutting tools (router tools or burr tools) selected for machining CFRPs, have complex geometries in cutting edges and surfaces, and therefore a traditional method of direct tool wear evaluation is not applicable. An acoustic emission (AE) sensing was employed for on-line monitoring of the performance of router tools to determine the relationship between AE signal and length of machining for different kinds of geometry of tools. The investigation showed that the router tool with a flat cutting edge has better performance by generating lower cutting force and better surface finish with no delamination on trimmed edges. The mathematical modeling for the prediction of cutting forces was also done using Artificial Neural Network and Regression Analysis. PMID:28773919

Discrete and continuum modelling of soil cutting

NASA Astrophysics Data System (ADS)

Coetzee, C. J.

2014-12-01

Both continuum and discrete methods are used to investigate the soil cutting process. The Discrete Element Method ( dem) is used for the discrete modelling and the Material-Point Method ( mpm) is used for continuum modelling. M pmis a so-called particle method or meshless finite element method. Standard finite element methods have difficulty in modelling the entire cutting process due to large displacements and deformation of the mesh. The use of meshless methods overcomes this problem. M pm can model large deformations, frictional contact at the soil-tool interface, and dynamic effects (inertia forces). In granular materials the discreteness of the system is often important and rotational degrees of freedom are active, which might require enhanced theoretical approaches like polar continua. In polar continuum theories, the material points are considered to possess orientations. A material point has three degrees-of-freedom for rigid rotations, in addition to the three classic translational degrees-of-freedom. The Cosserat continuum is the most transparent and straightforward extension of the nonpolar (classic) continuum. Two-dimensional dem and mpm (polar and nonpolar) simulations of the cutting problem are compared to experiments. The drag force and flow patterns are compared using cohesionless corn grains as material. The corn macro (continuum) and micro ( dem) properties were obtained from shear and oedometer tests. Results show that the dilatancy angle plays a significant role in the flow of material but has less of an influence on the draft force. Nonpolar mpm is the most accurate in predicting blade forces, blade-soil interface stresses and the position and orientation of shear bands. Polar mpm fails in predicting the orientation of the shear band, but is less sensitive to mesh size and mesh orientation compared to nonpolar mpm. dem simulations show less material dilation than observed during experiments.

Double diameter boring tool

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ashbaugh, F.N.; Murry, K.R.

A method of boring two concentric holes of different depths is described utilizing an elongated boring tool having a tool axis of rotation, a longitudinally disposed tool centerline axis, and first and second transverse cutting edges at one end thereof extending across the boring tool, the second cutting edge being longitudinally rearwardly recessed with respect to the first cutting edge. The method consists of inserting the boring tool into an adjustable boring head, adjusting a distance B between the tool centerline axis and the tool axis of rotation such that the tool axis of rotation intersects a first boring areamore » of the first cutting edge; and boring the concentric holes having respectively larger and smaller diameters.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bunshah, R.F.; Shabaik, A.H.

The process of Activated Reactive Evaporation is used to synthesize superhard materials like carbides, oxides, nitrides, ultrafine grain cermets. The deposits are characterized by hardness, microstructure and lattice parameter measurements. The synthesis and characterization of TiC-Ni cermets, Al/sub 2/O/sub 3/ and VC-TiC alloy carbides is given. Tools of different coating characteristics are tested for machining performance at different speeds and feeds. The machining evaluation and the selection of coatings is based on the rate of deterioration of the costing, tool temperature, and cutting forces. Tool life tests show coated high speed steel tools show a 300% improvement in tool life.more » (Author) (GRA)« less

A study examining the effects of water-miscible cutting fluids for end milling process of carbon fiber reinforced plastic

NASA Astrophysics Data System (ADS)

Anan, Ruito; Matsuoka, Hironori; Ono, Hajime; Ryu, Takahiro; Nakae, Takashi; Shuto, Schuichi; Watanabe, Suguru; Sato, Yuta

2017-04-01

This study examined the improvements to the tool life and finished surface roughness by using water-miscible cutting fluids in carbon fiber reinforced plastics end milling. In cutting tests, it was found that the use of emulsion type, soluble type, and solution type cutting fluids improved tool life compared with the case of dry cutting. Specifically, significant differences in tool life were observed at a high cutting speed of 171 m/min. In addition, the finished surface exhibited a low level of roughness when the solution type cutting fluid was used, regardless of the cutting speed.

Preset pivotal tool holder

DOEpatents

Asmanes, Charles

1979-01-01

A tool fixture is provided for precise pre-alignment of a radiused edge cutting tool in a tool holder relative to a fixed reference pivot point established on said holder about which the tool holder may be selectively pivoted relative to the fixture base member to change the contact point of the tool cutting edge with a workpiece while maintaining the precise same tool cutting radius relative to the reference pivot point.

Test drilling in basalts, Lalamilo area, South Kohala District, Hawaii

USGS Publications Warehouse

Teasdale, Warren E.

1980-01-01

Test drilling has determined that a downhole-percussion airhammer can be used effectively to drill basalts in Hawaii. When used in conjunction with a foam-type drilling fluid, the hammer-bit penetration rate was rapid. Continuous drill cuttings from the materials penetrated were obtained throughout the borehole except from extremely fractured or weathered basalt zones where circulation was lost or limited. Cementing of these zones as soon as encountered reduced problems of stuck tools, washouts, and loss of drill-cuttings. Supplies and logistics on the Hawaiian Islands, always a major concern, require that all anticipated drilling supplies, spare rig and tool parts, drilling muds and additives, foam, and miscellaneous hardware be on hand before starting to drill. If not, the resulting rig downtime is costly in both time and money. (USGS)

High Speed Metal Removal

DTIC Science & Technology

1982-10-01

AISI 1340, 4140 , 4340, and HF-1) which are commonly used in large caliber projectile manufacture were machined at...Tool Load Data for AISI 1340 "finishing" cuts Life-Line Data for AISI 4140 "roughing" cuts Tool Wear-Land Chart Data for AISI 4140 - "roughing...34 cuts; 570 Ceramic Coated Carbide Tool Wear-Land Chart Data for AISI 4140 - "roughing" cuts; G-10 Ceramic- Tool Wear-Land Chart Data for AISI 4140

Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Hoffman, David S.; Mcferrin, David C.; Daniel, Ronald L., Jr.; Coby, John B., Jr.; Dawson, Sidney G.

1995-01-01

Cutting tool proposed for use in shaving weld beads flush with adjacent surfaces of weldments. Modified version of commercial pneumatically driven rotary cutting tool, cutting wheel of which turns at speeds sufficient for machining nickel alloys, titanium, and stainless steels. Equipped with forward-mounted handle and rear-mounted skid plate to maximize control and reduce dependence on skill of technician.

Surface dimpling on rotating work piece using rotation cutting tool

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bhapkar, Rohit Arun; Larsen, Eric Richard

A combined method of machining and applying a surface texture to a work piece and a tool assembly that is capable of machining and applying a surface texture to a work piece are disclosed. The disclosed method includes machining portions of an outer or inner surface of a work piece. The method also includes rotating the work piece in front of a rotating cutting tool and engaging the outer surface of the work piece with the rotating cutting tool to cut dimples in the outer surface of the work piece. The disclosed tool assembly includes a rotating cutting tool coupledmore » to an end of a rotational machining device, such as a lathe. The same tool assembly can be used to both machine the work piece and apply a surface texture to the work piece without unloading the work piece from the tool assembly.« less

Effect of cutting fluids and cutting conditions on surface integrity and tool wear in turning of Inconel 713C

NASA Astrophysics Data System (ADS)

Hikiji, R.

2018-01-01

The trend toward downsizing of engines helps to increase the number of turbochargers around Europe. As for the turbocharger, the temperature of the exhaust gas is so high that the parts made of nickel base super alloy Inconel 713C are used as high temperature strength metals. External turning of Inconel 713C which is used as the actual automotive parts was carried out. The effect of the cutting fluids and cutting conditions on the surface integrity and tool wear was investigated, considering global environment and cost performance. As a result, in the range of the cutting conditions used this time, when the depth of cut was small, the good surface integrity and tool life were obtained. However, in the case of the large corner radius, it was found that the more the cutting length increased, the more the tool wear increased. When the cutting length is so large, the surface integrity and tool life got worse. As for the cutting fluids, it was found that the synthetic type showed better performance in the surface integrity and tool life than the conventional emulsion. However, it was clear that the large corner radius made the surface roughness and tool life good, but it affected the size error etc. in machining the workpiece held in a cantilever style.

Effects of random aspects of cutting tool wear on surface roughness and tool life

NASA Astrophysics Data System (ADS)

Nabil, Ben Fredj; Mabrouk, Mohamed

2006-10-01

The effects of random aspects of cutting tool flank wear on surface roughness and on tool lifetime, when turning the AISI 1045 carbon steel, were studied in this investigation. It was found that standard deviations corresponding to tool flank wear and to the surface roughness increase exponentially with cutting time. Under cutting conditions that correspond to finishing operations, no significant differences were found between the calculated values of the capability index C p at the steady-state region of the tool flank wear, using the best-fit method or the Box-Cox transformation, or by making the assumption that the surface roughness data are normally distributed. Hence, a method to establish cutting tool lifetime could be established that simultaneously respects the desired average of surface roughness and the required capability index.

Analyzing the effect of tool edge radius on cutting temperature in micro-milling process

NASA Astrophysics Data System (ADS)

Liang, Y. C.; Yang, K.; Zheng, K. N.; Bai, Q. S.; Chen, W. Q.; Sun, G. Y.

2010-10-01

Cutting heat is one of the important physical subjects in the cutting process. Cutting heat together with cutting temperature produced by the cutting process will directly have effects on the tool wear and the life as well as on the workpiece processing precision and surface quality. The feature size of the workpiece is usually several microns. Thus, the tiny changes of cutting temperature will affect the workpiece on the surface quality and accuracy. Therefore, cutting heat and temperature generated in micro-milling will have significantly different effect than the one in the traditional tools cutting. In this paper, a two-dimensional coupled thermal-mechanical finite element model is adopted to determine thermal fields and cutting temperature during the Micro-milling process, by using software Deform-2D. The effect of tool edge radius on effective stress, effective strain, velocity field and cutting temperature distribution in micro-milling of aluminum alloy Al2024-T6 were investigated and analyzed. Also, the transient cutting temperature distribution was simulated dynamically. The simulation results show that the cutting temperature in Micro-milling is lower than those occurring in conventional milling processes due to the small loads and low cutting velocity. With increase of tool edge radius, the maximum temperature region gradually occurs on the contact region between finished surfaced and flank face of micro-cutter, instead of the rake face or the corner of micro-cutter. And this phenomenon shows an obvious size effect.

Assessment of wear dependence parameters in complex model of cutting tool wear

NASA Astrophysics Data System (ADS)

Antsev, A. V.; Pasko, N. I.; Antseva, N. V.

2018-03-01

This paper addresses wear dependence of the generic efficient life period of cutting tools taken as an aggregate of the law of tool wear rate distribution and dependence of parameters of this law's on the cutting mode, factoring in the random factor as exemplified by the complex model of wear. The complex model of wear takes into account the variance of cutting properties within one batch of tools, variance in machinability within one batch of workpieces, and the stochastic nature of the wear process itself. A technique of assessment of wear dependence parameters in a complex model of cutting tool wear is provided. The technique is supported by a numerical example.

Fabrication of Single Crystal MgO Capsules

NASA Technical Reports Server (NTRS)

Danielson, Lisa

2012-01-01

A method has been developed for machining MgO crystal blocks into forms for containing metallic and silicate liquids at temperatures up to 2,400 C, and pressures up to at least 320 kilobars. Possible custom shapes include tubes, rods, insulators, capsules, and guides. Key differences in this innovative method include drilling along the crystallographic zone axes, use of a vibration minimizing material to secure the workpiece, and constant flushing of material swarf with a cooling medium/lubricant (water). A single crystal MgO block is cut into a section .5 mm thick, 1 cm on a side, using a low-speed saw with a 0.004 blade. The cut is made parallel to the direction of cleavage. The block may be cut to any thickness to achieve the desired length of the piece. To minimize drilling vibrations, the MgO block is mounted on a piece of adhesive putty in a vise. The putty wad cradles the bottom half of the entire block. Diamond coring tools are used to drill the MgO to the desired custom shape, with water used to wet and wash the surface of swarf. Compressed air may also be used to remove swarf during breaks in drilling. The MgO workpiece must be kept cool at all times with water. After all the swarf is rinsed off, the piece is left to dry overnight. If the workpiece is still attached to the base of the MgO block after drilling, it may be cut off by using a diamond cutoff wheel on a rotary hand tool or by using a low-speed saw.

Investigation of wear land and rate of locally made HSS cutting tool

NASA Astrophysics Data System (ADS)

Afolalu, S. A.; Abioye, A. A.; Dirisu, J. O.; Okokpujie, I. P.; Ajayi, O. O.; Adetunji, O. R.

2018-04-01

Production technology and machining are inseparable with cutting operation playing important roles. Investigation of wear land and rate of cutting tool developed locally (C=0.56%) with an HSS cutting tool (C=0.65%) as a control was carried out. Wear rate test was carried out using Rotopol -V and Impact tester. The samples (12) of locally made cutting tools and one (1) sample of a control HSS cutting tool were weighed to get the initial weight and grit was fixed at a point for the sample to revolve at a specific time of 10 mins interval. Approach of macro transfer particles that involved mechanism of abrasion and adhesion which was termed as mechanical wear to handle abrasion adhesion processes was used in developing equation for growth wear at flank. It was observed from the wear test that best minimum wear rate of 1.09 × 10-8 and 2.053 × 10-8 for the tools developed and control were measured. MATLAB was used to simulate the wear land and rate under different conditions. Validated results of both the experimental and modeling showed that cutting speed has effect on wear rate while cutting time has predicted measure on wear land. Both experimental and modeling result showed best performances of tools developed over the control.

Investigation of machinability characteristics on EN47 steel for cutting force and tool wear using optimization technique

NASA Astrophysics Data System (ADS)

M, Vasu; Shivananda Nayaka, H.

2018-06-01

In this experimental work dry turning process carried out on EN47 spring steel with coated tungsten carbide tool insert with 0.8 mm nose radius are optimized by using statistical technique. Experiments were conducted at three different cutting speeds (625, 796 and 1250 rpm) with three different feed rates (0.046, 0.062 and 0.093 mm/rev) and depth of cuts (0.2, 0.3 and 0.4 mm). Experiments are conducted based on full factorial design (FFD) 33 three factors and three levels. Analysis of variance is used to identify significant factor for each output response. The result reveals that feed rate is the most significant factor influencing on cutting force followed by depth of cut and cutting speed having less significance. Optimum machining condition for cutting force obtained from the statistical technique. Tool wear measurements are performed with optimum condition of Vc = 796 rpm, ap = 0.2 mm, f = 0.046 mm/rev. The minimum tool wear observed as 0.086 mm with 5 min machining. Analysis of tool wear was done by confocal microscope it was observed that tool wear increases with increasing cutting time.

Effects of Different Cutting Patterns and Experimental Conditions on the Performance of a Conical Drag Tool

NASA Astrophysics Data System (ADS)

Copur, Hanifi; Bilgin, Nuh; Balci, Cemal; Tumac, Deniz; Avunduk, Emre

2017-06-01

This study aims at determining the effects of single-, double-, and triple-spiral cutting patterns; the effects of tool cutting speeds on the experimental scale; and the effects of the method of yield estimation on cutting performance by performing a set of full-scale linear cutting tests with a conical cutting tool. The average and maximum normal, cutting and side forces; specific energy; yield; and coarseness index are measured and compared in each cutting pattern at a 25-mm line spacing, at varying depths of cut per revolution, and using two cutting speeds on five different rock samples. The results indicate that the optimum specific energy decreases by approximately 25% with an increasing number of spirals from the single- to the double-spiral cutting pattern for the hard rocks, whereas generally little effect was observed for the soft- and medium-strength rocks. The double-spiral cutting pattern appeared to be more effective than the single- or triple-spiral cutting pattern and had an advantage of lower side forces. The tool cutting speed had no apparent effect on the cutting performance. The estimation of the specific energy by the yield based on the theoretical swept area was not significantly different from that estimated by the yield based on the muck weighing, especially for the double- and triple-spiral cutting patterns and with the optimum ratio of line spacing to depth of cut per revolution. This study also demonstrated that the cutterhead and mechanical miner designs, semi-theoretical deterministic computer simulations and empirical performance predictions and optimization models should be based on realistic experimental simulations. Studies should be continued to obtain more reliable results by creating a larger database of laboratory tests and field performance records for mechanical miners using drag tools.

Wear and breakage monitoring of cutting tools by an optical method: theory

NASA Astrophysics Data System (ADS)

Li, Jianfeng; Zhang, Yongqing; Chen, Fangrong; Tian, Zhiren; Wang, Yao

1996-10-01

An essential part of a machining system in the unmanned flexible manufacturing system, is the ability to automatically change out tools that are worn or damaged. An optoelectronic method for in situ monitoring of the flank wear and breakage of cutting tools is presented. A flank wear estimation system is implemented in a laboratory environment, and its performance is evaluated through turning experiments. The flank wear model parameters that need to be known a priori are determined through several preliminary experiments, or from data available in the literature. The resulting cutting conditions are typical of those used in finishing cutting operations. Through time and amplitude domain analysis of the cutting tool wear states and breakage states, it is found that the original signal digital specificity (sigma) 2x and the self correlation coefficient (rho) (m) can reflect the change regularity of the cutting tool wear and break are determined, but which is not enough due to the complexity of the wear and break procedure of cutting tools. Time series analysis and frequency spectrum analysis will be carried out, which will be described in the later papers.

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

DOE PAGES

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.; ...

2018-04-04

We present that friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developedmore » to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.« less

ICALEO '91 - Laser materials processing; Proceedings of the Meeting, San Jose, CA, Nov. 3-8, 1991

NASA Astrophysics Data System (ADS)

Metzbower, Edward A.; Beyer, Eckhard; Matsunawa, Akira

Consideration is given to new developments in LASERCAV technology, modeling of deep penetration laser welding, the theory of radiative transfer in the plasma of the keyhole in penetration laser welding, a synchronized laser-video camera system study of high power laser material interactions, laser process monitoring with dual wavelength optical sensors, new devices for on-line process diagnostics during laser machining, and the process development for a portable Nd:YAG laser materials processing system. Attention is also given to laser welding of alumina-reinforced 6061 aluminum alloy composite, the new trend of laser materials processing, optimization of the laser cutting process for thin section stainless steels, a new nozzle concept for cutting with high power lasers, rapid solidification effects during laser welding, laser surface modification of a low carbon steel with tungsten carbide and carbon, absorptivity of a polarized beam during laser hardening, and laser surface melting of 440 C tool steel. (No individual items are abstracted in this volume)

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.

The friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For the welds in lap configuration, an enhancement to this technology is made by introducing a short hard insert, referred to as cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanically coupled computational model employing coupled Eulerian-Lagrangian approach is developed to quantitativelymore » capture the morphology of these interlocks during the FSW process. The simulations using developed model are validated by the experimental observations.The identified interface morphology coupled with the predicted temperature field from this process-structure model can then be used to estimate the post-weld microstructure and joint strength.« less

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.

We present that friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developedmore » to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.« less

Influence of Surface Features for Increased Heat Dissipation on Tool Wear

PubMed Central

Beno, Tomas; Hoier, Philipp; Wretland, Anders

2018-01-01

The critical problems faced during the machining process of heat resistant superalloys, (HRSA), is the concentration of heat in the cutting zone and the difficulty in dissipating it. The concentrated heat in the cutting zone has a negative influence on the tool life and surface quality of the machined surface, which in turn, contributes to higher manufacturing costs. This paper investigates improved heat dissipation from the cutting zone on the tool wear through surface features on the cutting tools. Firstly, the objective was to increase the available surface area in high temperature regions of the cutting tool. Secondly, multiple surface features were fabricated for the purpose of acting as channels in the rake face to create better access for the coolant to the proximity of the cutting edge. The purpose was thereby to improve the cooling of the cutting edge itself, which exhibits the highest temperature during machining. These modified inserts were experimentally investigated in face turning of Alloy 718 with high-pressure coolant. Overall results exhibited that surface featured inserts decreased flank wear, abrasion of the flank face, cutting edge deterioration and crater wear probably due to better heat dissipation from the cutting zone. PMID:29693579

Machine Shop. Module 5: Lathes. Instructor's Guide.

ERIC Educational Resources Information Center

Nobles, Jack

This document consists of materials for a 10-unit course on the following topics: (1) types and parts of lathes; (2) lathe accessories, maintenance, and safety; (3) lathe operations and tooling; (4) lathe calculations; (5) lathe taper and thread applications; (6) planning considerations; (7) cutting fluids, lathe center alignment, and lathe gaps;…

High Power Laser Processing Of Materials

NASA Astrophysics Data System (ADS)

Martyr, D. R.; Holt, T.

1987-09-01

The first practical demonstration of a laser device was in 1960 and in the following years, the high power carbon dioxide laser has matured as an industrial machine tool. Modern carbon dioxide gas lasers can be used for cutting, welding, heat treatment, drilling, scribing and marking. Since their invention over 25 years ago they are now becoming recognised as highly reliable devices capable of achieving huge savings in production costs in many situations. This paper introduces the basic laser processing techniques of cutting, welding and heat treatment as they apply to the most common engineering materials. Typical processing speeds achieved with a wide range of laser powers are reported. Accuracies achievable and fit-up tolerances required are presented. Methods of integrating lasers with machine tools are described and their suitability in a wide range of manufacturing industries is described by reference to recent installations. Examples from small batch manufacturing, high volume production using dedicated laser welding equipment, and high volume manufacturing using 'flexible' automated laser welding equipment are described Future applications of laser processing are suggested by reference to current process developments.

Study of process parameter on mist lubrication of Titanium (Grade 5) alloy

NASA Astrophysics Data System (ADS)

Maity, Kalipada; Pradhan, Swastik

2017-02-01

This paper deals with the machinability of Ti-6Al-4V alloy with mist cooling lubrication using carbide inserts. The influence of process parameter on the cutting forces, evolution of tool wear, surface finish of the workpiece, material removal rate and chip reduction coefficient have been investigated. Weighted principal component analysis coupled with grey relational analysis optimization is applied to identify the optimum setting of the process parameter. Optimal condition of the process parameter was cutting speed at 160 m/min, feed at 0.16 mm/rev and depth of cut at 1.6 mm. Effects of cutting speed and depth of cut on the type of chips formation were observed. Most of the chips forms were long tubular and long helical type. Image analyses of the segmented chip were examined to study the shape and size of the saw tooth profile of serrated chips. It was found that by increasing cutting speed from 95 m/min to 160 m/min, the free surface lamella of the chips increased and the visibility of the saw tooth segment became clearer.

Effects of machining parameters on tool life and its optimization in turning mild steel with brazed carbide cutting tool

NASA Astrophysics Data System (ADS)

Dasgupta, S.; Mukherjee, S.

2016-09-01

One of the most significant factors in metal cutting is tool life. In this research work, the effects of machining parameters on tool under wet machining environment were studied. Tool life characteristics of brazed carbide cutting tool machined against mild steel and optimization of machining parameters based on Taguchi design of experiments were examined. The experiments were conducted using three factors, spindle speed, feed rate and depth of cut each having three levels. Nine experiments were performed on a high speed semi-automatic precision central lathe. ANOVA was used to determine the level of importance of the machining parameters on tool life. The optimum machining parameter combination was obtained by the analysis of S/N ratio. A mathematical model based on multiple regression analysis was developed to predict the tool life. Taguchi's orthogonal array analysis revealed the optimal combination of parameters at lower levels of spindle speed, feed rate and depth of cut which are 550 rpm, 0.2 mm/rev and 0.5mm respectively. The Main Effects plot reiterated the same. The variation of tool life with different process parameters has been plotted. Feed rate has the most significant effect on tool life followed by spindle speed and depth of cut.

Investigation into the Effects of Textural Properties on Cuttability Performance of a Chisel Tool

NASA Astrophysics Data System (ADS)

Tumac, Deniz; Copur, Hanifi; Balci, Cemal; Er, Selman; Avunduk, Emre

2018-04-01

The main objective of this study is to investigate the effect of textural properties of stones on cutting performance of a standard chisel tool. Therewithal, the relationships between textural properties and cutting performance parameters and physical and mechanical properties were statistically analyzed. For this purpose, physical and mechanical property tests and mineralogical and petrographic analyses were carried out on eighteen natural stone samples, which can be grouped into three fundamentally different geological origins, i.e., metamorphic, igneous, and sedimentary. Then, texture coefficient analyses were performed on the samples. To determine the cuttability of the stones; the samples were cut with a portable linear cutting machine using a standard chisel tool at different depths of cut in unrelieved (non-interactive) cutting mode. The average and maximum forces (normal and cutting) and specific energy were measured, and the obtained values were correlated with texture coefficient, packing weighting, and grain size. With reference to the relation between depth of cut and cutting performance of the chisel tool for three types of natural stone groups, specific energy decreases with increasing depth of cut, and cutting forces increase in proportion to the depth of cut. The same is observed for the relationship between packing weighting and both of specific energy and cutter forces. On the other hand, specific energy and the forces decrease while grain size increases. Based on the findings of the present study, texture coefficient has strong correlation with specific energy. Generally, the lower depth of cut values in cutting tests shows higher and more reliable correlations with texture coefficient than the increased depth of cut. The results of cutting tests show also that, at a lower depth of cut (less than 1.5 mm), even stronger correlations can be observed between texture coefficient and cutting performance. Experimental studies indicate that cutting performance of chisel tools can be predicted based on texture coefficients of the natural stones.

Aspects of the tribological behaviour of powders recycled from rapid steel treated sub-zero

NASA Astrophysics Data System (ADS)

Radu, S.; Ciobanu, M.

2017-02-01

The recycling of high-alloyed steels represents a significant opportunity in Powder Metallurgy as it permits the use of raw materials with relatively low prices compared to the conventional methods. Recycling can be achieved by two methods: from spraying debris resulted from worn cutting tools and processes obtained from processing chip drilling and re-sharpening of tools. The research aims to confirm that wastes from rapid steels can become, by the successive processing, metal powders that can thereafter be used for cutting tools of lathe type removable plate. After pressing and sintering the recycling powder, cylindrical samples were obtained that were subsequently applied a subcritical annealing. Wear tests conducted on a tribometer type TRB-01-02541 confirmed that their wear resistance is superior to the same samples that were sintered, hardened and tempered in oil. This paper was accepted for publication in Proceedings after double peer reviewing process but was not presented at the Conference ROTRIB’16.

Study on residual stresses in ultrasonic torsional vibration assisted micro-milling

NASA Astrophysics Data System (ADS)

Lu, Zesheng; Hu, Haijun; Sun, Yazhou; Sun, Qing

2010-10-01

It is well known that machining induced residual stresses can seriously affect the dimensional accuracy, corrosion and wear resistance, etc., and further influence the longevity and reliability of Micro-Optical Components (MOC). In Ultrasonic Torsional Vibration Assisted Micro-milling (UTVAM), cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank are the main factors which affect residual stresses. A 2D model of UTVAM was established with FE analysis software ABAQUS. Johnson-Cook's flow stress model and shear failure principle are used as the workpiece material model and failure principle, while friction between tool and workpiece uses modified Coulomb's law whose sliding friction area is combined with sticking friction. By means of FEA, the influence rules of cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank on residual stresses are obtained, which provides a basis for choosing optimal process parameters and improving the longevity and reliability of MOC.

Effects of Cutting Edge Microgeometry on Residual Stress in Orthogonal Cutting of Inconel 718 by FEM.

PubMed

Shen, Qi; Liu, Zhanqiang; Hua, Yang; Zhao, Jinfu; Lv, Woyun; Mohsan, Aziz Ul Hassan

2018-06-14

Service performance of components such as fatigue life are dramatically influenced by the machined surface and subsurface residual stresses. This paper aims at achieving a better understanding of the influence of cutting edge microgeometry on machined surface residual stresses during orthogonal dry cutting of Inconel 718. Numerical and experimental investigations have been conducted in this research. The cutting edge microgeometry factors of average cutting edge radius S¯, form-factor K , and chamfer were investigated. An increasing trend for the magnitudes of both tensile and compressive residual stresses was observed by using larger S¯ or introducing a chamfer on the cutting edges. The ploughing depth has been predicted based on the stagnation zone. The increase of ploughing depth means that more material was ironed on the workpiece subsurface, which resulted in an increase in the compressive residual stress. The thermal loads were leading factors that affected the surface tensile residual stress. For the unsymmetrical honed cutting edge with K = 2, the friction between tool and workpiece and tensile residual stress tended to be high, while for the unsymmetrical honed cutting edge with K = 0.5, the high ploughing depth led to a higher compressive residual stress. This paper provides guidance for regulating machine-induced residual stress by edge preparation.

Old stones' song: use-wear experiments and analysis of the Oldowan quartz and quartzite assemblage from Kanjera South (Kenya).

PubMed

Lemorini, Cristina; Plummer, Thomas W; Braun, David R; Crittenden, Alyssa N; Ditchfield, Peter W; Bishop, Laura C; Hertel, Fritz; Oliver, James S; Marlowe, Frank W; Schoeninger, Margaret J; Potts, Richard

2014-07-01

Evidence of Oldowan tools by ∼2.6 million years ago (Ma) may signal a major adaptive shift in hominin evolution. While tool-dependent butchery of large mammals was important by at least 2.0 Ma, the use of artifacts for tasks other than faunal processing has been difficult to diagnose. Here we report on use-wear analysis of ∼2.0 Ma quartz and quartzite artifacts from Kanjera South, Kenya. A use-wear framework that links processing of specific materials and tool motions to their resultant use-wear patterns was developed. A blind test was then carried out to assess and improve the efficacy of this experimental use-wear framework, which was then applied to the analysis of 62 Oldowan artifacts from Kanjera South. Use-wear on a total of 23 artifact edges was attributed to the processing of specific materials. Use-wear on seven edges (30%) was attributed to animal tissue processing, corroborating zooarchaeological evidence for butchery at the site. Use-wear on 16 edges (70%) was attributed to the processing of plant tissues, including wood, grit-covered plant tissues that we interpret as underground storage organs (USOs), and stems of grass or sedges. These results expand our knowledge of the suite of behaviours carried out in the vicinity of Kanjera South to include the processing of materials that would be 'invisible' using standard archaeological methods. Wood cutting and scraping may represent the production and/or maintenance of wooden tools. Use-wear related to USO processing extends the archaeological evidence for hominin acquisition and consumption of this resource by over 1.5 Ma. Cutting of grasses, sedges or reeds may be related to a subsistence task (e.g., grass seed harvesting, cutting out papyrus culm for consumption) and/or a non-subsistence related task (e.g., production of 'twine,' simple carrying devices, or bedding). These results highlight the adaptive significance of lithic technology for hominins at Kanjera. Copyright © 2014 Elsevier Ltd. All rights reserved.

Comparative study of coated and uncoated tool inserts with dry machining of EN47 steel using Taguchi L9 optimization technique

NASA Astrophysics Data System (ADS)

Vasu, M.; Shivananda, Nayaka H.

2018-04-01

EN47 steel samples are machined on a self-centered lathe using Chemical Vapor Deposition of coated TiCN/Al2O3/TiN and uncoated tungsten carbide tool inserts, with nose radius 0.8mm. Results are compared with each other and optimized using statistical tool. Input (cutting) parameters that are considered in this work are feed rate (f), cutting speed (Vc), and depth of cut (ap), the optimization criteria are based on the Taguchi (L9) orthogonal array. ANOVA method is adopted to evaluate the statistical significance and also percentage contribution for each model. Multiple response characteristics namely cutting force (Fz), tool tip temperature (T) and surface roughness (Ra) are evaluated. The results discovered that coated tool insert (TiCN/Al2O3/TiN) exhibits 1.27 and 1.29 times better than the uncoated tool insert for tool tip temperature and surface roughness respectively. A slight increase in cutting force was observed for coated tools.

Influence of particle size on Cutting Forces and Surface Roughness in Machining of B4Cp - 6061 Aluminium Matrix Composites

NASA Astrophysics Data System (ADS)

Hiremath, Vijaykumar; Badiger, Pradeep; Auradi, V.; Dundur, S. T.; Kori, S. A.

2016-02-01

Amongst advanced materials, metal matrix composites (MMC) are gaining importance as materials for structural applications in particular, particulate reinforced aluminium MMCs have received considerable attention due to their superior properties such as high strength to weight ratio, excellent low-temperature performance, high wear resistance, high thermal conductivity. The present study aims at studying and comparing the machinability aspects of B4Cp reinforced 6061Al alloy metal matrix composites reinforced with 37μm and 88μm particulates produced by stir casting method. The micro structural characterization of the prepared composites is done using Scanning Electron Microscopy equipped with EDX analysis (Hitachi Su-1500 model) to identify morphology and distribution of B4C particles in the 6061Al matrix. The specimens are turned on a conventional lathe machine using a Polly crystalline Diamond (PCD) tool to study the effect of particle size on the cutting forces and the surface roughness under varying machinability parameters viz., Cutting speed (29-45 m/min.), Feed rate (0.11-0.33 mm/rev.) and depth of cut (0.5-1mm). Results of micro structural characterization revealed fairly uniform distribution of B4C particles (in both cases i.e., 37μm and 88μm) in 6061Al matrix. The surface roughness of the composite is influenced by cutting speed. The feed rate and depth of cut have a negative influence on surface roughness. The cutting forces decreased with increase in cutting speed whereas cutting forces increased with increase in feed and depth of cut. Higher cutting forces are noticed while machining Al6061 base alloy compared to reinforced composites. Surface finish is high during turning of the 6061Al base alloy and surface roughness is high with 88μm size particle reinforced composites. As the particle size increases Surface roughness also increases.

Microwave coupler and method

DOEpatents

Holcombe, C.E.

1984-11-29

The present invention is directed to a microwave coupler for enhancing the heating or metallurgical treatment of materials within a cold-wall, rapidly heated cavity as provided by a microwave furnace. The coupling material of the present invention is an alpha-rhombohedral-boron-derivative-structure material such as boron carbide or boron silicide which can be appropriately positioned as a susceptor within the furnace to heat other material or be in powder particulate form so that composites and structures of boron carbide such as cutting tools, grinding wheels and the like can be rapidly and efficiently formed within microwave furnaces.

Microwave coupler and method

DOEpatents

Holcombe, Cressie E.

1985-01-01

The present invention is directed to a microwave coupler for enhancing the heating or metallurgical treatment of materials within a cold-wall, rapidly heated cavity as provided by a microwave furnace. The coupling material of the present invention is an alpha-rhombohedral-boron-derivative-structure material such as boron carbide or boron silicide which can be appropriately positioned as a susceptor within the furnace to heat other material or be in powder particulate form so that composites and structures of boron carbide such as cutting tools, grinding wheels and the like can be rapidly and efficiently formed within microwave furnaces.

Comprehensive surface treatment of high-speed steel tool

NASA Astrophysics Data System (ADS)

Fedorov, Sergey V.; Aleshin, Sergey V.; Swe, Min Htet; Abdirova, Raushan D.; Kapitanov, Alexey V.; Egorov, Sergey B.

2018-03-01

One of the promising directions of hardening of high-speed steel tool is the creation on their surface of the layered structures with the gradient of physic-chemical properties between the wear-resistant coatings to the base material. Among the methods of such surface modification, a special process takes place based on the use of pulsed high-intensity charged particle beams. The high speed of heating and cooling allows structural-phase transformations in the surface layer, which cannot be realized in a stationary mode. The treatment was conducted in a RITM-SP unit, which constitutes a combination of a source of low-energy high-current electron beams "RITM" and two magnetron spraying systems on a single vacuum chamber. The unit enables deposition of films on the surface of the desired product and subsequent liquid-phase mixing of materials of the film and the substrate by an intense pulse electron beam. The article discusses features of the structure of the subsurface layer of high-speed steel M2, modified by surface alloying of a low-energy high-current electron beam, and its effect on the wear resistance of the tool when dry cutting hard to machine Nickel alloy. A significant decrease of intensity of wear of high-speed steel with combined treatment happens due to the displacement of the zone of wear and decrease the radius of rounding of the cutting edge because of changes in conditions of interaction with the material being treated.

The influence of machining condition and cutting tool wear on surface roughness of AISI 4340 steel

NASA Astrophysics Data System (ADS)

Natasha, A. R.; Ghani, J. A.; Che Haron, C. H.; Syarif, J.

2018-01-01

Sustainable machining by using cryogenic coolant as the cutting fluid has been proven to enhance some machining outputs. The main objective of the current work was to investigate the influence of machining conditions; dry and cryogenic, as well as the cutting tool wear on the machined surface roughness of AISI 4340 steel. The experimental tests were performed using chemical vapor deposition (CVD) coated carbide inserts. The value of machined surface roughness were measured at 3 cutting intervals; beginning, middle, and end of the cutting based on the readings of the tool flank wear. The results revealed that cryogenic turning had the greatest influence on surface roughness when machined at lower cutting speed and higher feed rate. Meanwhile, the cutting tool wear was also found to influence the surface roughness, either improving it or deteriorating it, based on the severity and the mechanism of the flank wear.

Performance Monitoring Of A Computer Numerically Controlled (CNC) Lathe Using Pattern Recognition Techniques

NASA Astrophysics Data System (ADS)

Daneshmend, L. K.; Pak, H. A.

1984-02-01

On-line monitoring of the cutting process in CNC lathe is desirable to ensure unattended fault-free operation in an automated environment. The state of the cutting tool is one of the most important parameters which characterises the cutting process. Direct monitoring of the cutting tool or workpiece is not feasible during machining. However several variables related to the state of the tool can be measured on-line. A novel monitoring technique is presented which uses cutting torque as the variable for on-line monitoring. A classifier is designed on the basis of the empirical relationship between cutting torque and flank wear. The empirical model required by the on-line classifier is established during an automated training cycle using machine vision for off-line direct inspection of the tool.

Tubing and cable cutting tool

NASA Technical Reports Server (NTRS)

Mcsmith, D. D.; Richardson, J. I. (Inventor)

1984-01-01

A hand held hydraulic cutting tool was developed which is particularly useful in deactivating ejection seats in military aircraft rescue operations. The tool consists primarily of a hydraulic system composed of a fluid reservoir, a pumping piston, and an actuator piston. Mechanical cutting jaws are attached to the actuator piston rod. The hydraulic system is controlled by a pump handle. As the pump handle is operated the actuator piston rod is forced outward and thus the cutting jaws are forced together. The frame of the device is a flexible metal tubing which permits easy positioning of the tool cutting jaws in remote and normally inaccessible locations. Bifurcated cutting edges ensure removal of a section of the tubing or cable to thereby reduce the possibility of accidental reactivation of the tubing or cable being severed.

Machinability assessment of commercially pure titanium (CP-Ti) during turning operation: Application potential of GRA method

NASA Astrophysics Data System (ADS)

Khan, Akhtar; Maity, Kalipada

2018-03-01

This paper explores some of the vital machinability characteristics of commercially pure titanium (CP-Ti) grade 2. Experiments were conducted based on Taguchi’s L9 orthogonal array. The selected material was machined on a heavy duty lathe (Model: HMT NH26) using uncoated carbide inserts in dry cutting environment. The selected inserts were designated by ISO as SNMG 120408 (Model: K313) and manufactured by Kennametal. These inserts were rigidly mounted on a right handed tool holder PSBNR 2020K12. Cutting speed, feed rate and depth of cut were selected as three input variables whereas tool wear (VBc) and surface roughness (Ra) were the major attentions. In order to confirm an appreciable machinability of the work part, an optimal parametric combination was attained with the help of grey relational analysis (GRA) approach. Finally, a mathematical model was developed to exhibit the accuracy and acceptability of the proposed methodology using multiple regression equations. The results indicated that, the suggested model is capable of predicting overall grey relational grade within acceptable range.

Cost minimizing of cutting process for CNC thermal and water-jet machines

NASA Astrophysics Data System (ADS)

Tavaeva, Anastasia; Kurennov, Dmitry

2015-11-01

This paper deals with optimization problem of cutting process for CNC thermal and water-jet machines. The accuracy of objective function parameters calculation for optimization problem is investigated. This paper shows that working tool path speed is not constant value. One depends on some parameters that are described in this paper. The relations of working tool path speed depending on the numbers of NC programs frames, length of straight cut, configuration part are presented. Based on received results the correction coefficients for working tool speed are defined. Additionally the optimization problem may be solved by using mathematical model. Model takes into account the additional restrictions of thermal cutting (choice of piercing and output tool point, precedence condition, thermal deformations). At the second part of paper the non-standard cutting techniques are considered. Ones may lead to minimizing of cutting cost and time compared with standard cutting techniques. This paper considers the effectiveness of non-standard cutting techniques application. At the end of the paper the future research works are indicated.

On the influence of Ti-Al intermetallic coating architecture on mechanical properties and wear resistance of end mills

NASA Astrophysics Data System (ADS)

Vardanyan, E. L.; Budilov, V. V.; Ramazanov, K. N.; Ataullin, Z. R.

2017-07-01

Thin-film wear-resistant coatings are widely used to increase life and efficiency of metal cutting tools. This paper shows the results of a study on the influence of architecture (number, sequence and thickness of layers) of wear-resistant coatings on physical, mechanical and operational properties of end mills. Coatings consisting of alternating Ti-Al/Ti-Al-N layers of equal thickness demonstrated the best physical and mechanical properties. Durability of coated tools when processing materials from chromium-vanadium steel increased twice as compared to uncoated tools.

Influence of Cutting Parameters and Tool Wear on the Surface Integrity of Cobalt-Based Stellite 6 Alloy When Machined Under a Dry Cutting Environment

NASA Astrophysics Data System (ADS)

Yingfei, Ge; de Escalona, Patricia Muñoz; Galloway, Alexander

2017-01-01

The efficiency of a machining process can be measured by evaluating the quality of the machined surface and the tool wear rate. The research reported herein is mainly focused on the effect of cutting parameters and tool wear on the machined surface defects, surface roughness, deformation layer and residual stresses when dry milling Stellite 6, deposited by overlay on a carbon steel surface. The results showed that under the selected cutting conditions, abrasion, diffusion, peeling, chipping and breakage were the main tool wear mechanisms presented. Also the feed rate was the primary factor affecting the tool wear with an influence of 83%. With regard to the influence of cutting parameters on the surface roughness, the primary factors were feed rate and cutting speed with 57 and 38%, respectively. In addition, in general, as tool wear increased, the surface roughness increased and the deformation layer was found to be influenced more by the cutting parameters rather than the tool wear. Compressive residual stresses were observed in the un-machined surface, and when machining longer than 5 min, residual stress changed 100% from compression to tension. Finally, results showed that micro-crack initiation was the main mechanism for chip formation.

Use of non-standardised micro-destructive techniques in the characterization of traditional construction materials

NASA Astrophysics Data System (ADS)

Ioannou, Ioannis; Theodoridou, Magdalini; Modestou, Sevasti; Fournari, Revecca; Dagrain, Fabrice

2013-04-01

The characterization of material properties and the diagnosis of their state of weathering and conservation are three of the most important steps in the field of cultural heritage preservation. Several standardised experimental methods exist, especially for determining the material properties and their durability. However, they are limited in their application by the required size of test specimens and the controlled laboratory conditions needed to undertake the tests; this is especially true when the materials under study constitute immovable parts of heritage structures. The current use of other advanced methods of analysis, such as imaging techniques, in the aforementioned field of research offers invaluable results. However, these techniques may not always be accessible to the wider research community due to their complex nature and relatively high cost of application. This study presents innovative applications of two recently developed cutting techniques; the portable Drilling Resistance Measuring System (DRMS) and the scratch tool. Both methods are defined as micro-destructive, since they only destroy a very small portion of sample material. The general concept of both methods lies within the forces needed to cut a material by linear (scratch tool) or rotational (DRMS) cutting action; these forces are related to the mechanical properties of the material and the technological parameters applied on the tool. Therefore, for a given testing configuration, the only parameter influencing the forces applied is the strength of the material. These two techniques have been used alongside a series of standardised laboratory tests aiming at the correlation of various stone properties (density, porosity, dynamic elastic modulus and uniaxial compressive strength). The results prove the potential of both techniques in assessing the uniaxial compressive strength of stones. The scratch tool has also been used effectively to estimate the compressive strength of mud bricks. It therefore follows that both micro-destructive techniques may prove useful in the physico-mechanical characterization of materials which demand in-situ measurements or allow very limited sampling. Moreover, both techniques have been used, for the first time, to map the distribution of salts in building stone in the laboratory; micro-drilling was also applied in the same context in-situ. The results of the laboratory tests performed on limestone impregnated with sodium and magnesium sulfate confirm that both the scratch tool and the DRMS may successfully detect the location of the salt front, as they respond to pore clogging by salt crystals by providing increased scratching/drilling resistance values. Drilling and scratching of duplicate samples treated with a hydrophobic product show the sensitivity of both techniques as they clearly detect changes to the salt front location (i.e. cryptoflorescence) caused by surface treatments. Both techniques were also successful in highlighting the difference in the crystallisation location and pattern of magnesium sulphate and sodium chloride. In-situ application of the micro-drilling test demonstrated its potential for use in the assessment of masonry salt weathering; the results suggest that this technique may, in fact, be useful as a preventive measure against salt damage. Last but not least, both aforementioned novel micro-destructive techniques have been used to assess the effectiveness of commercially available consolidants. The results of the scratch tool have also been utilised to develop a tomography image of the samples under test. Scratching tomography may potentially be combined with in-situ micro-drilling tests to evaluate the effectiveness of consolidation treatments applied on monuments and historic buildings.

Improved tool grinding machine

DOEpatents

Dial, C.E. Sr.

The present invention relates to an improved tool grinding mechanism for grinding single point diamond cutting tools to precise roundness and radius specifications. The present invention utilizes a tool holder which is longitudinally displaced with respect to the remainder of the grinding system due to contact of the tool with the grinding surface with this displacement being monitored so that any variation in the grinding of the cutting surface such as caused by crystal orientation or tool thicknesses may be compensated for during the grinding operation to assure the attainment of the desired cutting tool face specifications.

Tool grinding machine

DOEpatents

Dial, Sr., Charles E.

1980-01-01

The present invention relates to an improved tool grinding mechanism for grinding single point diamond cutting tools to precise roundness and radius specifications. The present invention utilizes a tool holder which is longitudinally displaced with respect to the remainder of the grinding system due to contact of the tool with the grinding surface with this displacement being monitored so that any variation in the grinding of the cutting surface such as caused by crystal orientation or tool thickness may be compensated for during the grinding operation to assure the attainment of the desired cutting tool face specifications.

Investigation of roughing machining simulation by using visual basic programming in NX CAM system

NASA Astrophysics Data System (ADS)

Hafiz Mohamad, Mohamad; Nafis Osman Zahid, Muhammed

2018-03-01

This paper outlines a simulation study to investigate the characteristic of roughing machining simulation in 4th axis milling processes by utilizing visual basic programming in NX CAM systems. The selection and optimization of cutting orientation in rough milling operation is critical in 4th axis machining. The main purpose of roughing operation is to approximately shape the machined parts into finished form by removing the bulk of material from workpieces. In this paper, the simulations are executed by manipulating a set of different cutting orientation to generate estimated volume removed from the machine parts. The cutting orientation with high volume removal is denoted as an optimum value and chosen to execute a roughing operation. In order to run the simulation, customized software is developed to assist the routines. Operations build-up instructions in NX CAM interface are translated into programming codes via advanced tool available in the Visual Basic Studio. The codes is customized and equipped with decision making tools to run and control the simulations. It permits the integration with any independent program files to execute specific operations. This paper aims to discuss about the simulation program and identifies optimum cutting orientations for roughing processes. The output of this study will broaden up the simulation routines performed in NX CAM systems.

Study of the Vibration Effect on the Cutting Forces and Roughness of Slub Milling

NASA Astrophysics Data System (ADS)

Germa, S.; Estrems Amestoy, M.; Sánchez Reinoso, H. T.; Franco Chumillas, P.

2009-11-01

For the planning process of slab milling operations, the vibration of the tool is the main factor to be considered. Under vibration conditions, the effect of the small displacements of the cutting tool and the cutting forces on the chip thickness must be minimized in order to avoid undesirable consequences, such as the fast flank wear, superficial defects and roughness increase. In this work, a mathematical model is developed to take into account the combined effect of the cutting tool and workpiece oscillation, as well as the axial errors of different milling tool tips. As a result, the model estimates the variation of the cutting forces and the ideal surface roughness.

Electrode/workpiece combinations

NASA Astrophysics Data System (ADS)

Benedict, J. J.

1989-10-01

Of the many machine tool operations available in the shop today, plunge cut Electrical Discharge Machining (EDM) has become an increasingly useful method of materials fabrication. It is a necessary tool for the research and development type of work performed at the Lawrence Livermore National Laboratory (LLNL). With advancing technology, plunge cut EDMs are more efficient, faster, have greater accuracy and are able to produce better surface finishes. They have been in the past and will continue to be an important part of the production of quality parts in both the Precision and NC Shop. It should be kept in mind that as a non-traditional machining process, EDMing is a time consuming process that can be a very expensive method of producing parts. For this reason, it must be used in the most efficient manner in order to make it a cost-effective means of fabrication, although technology has advanced to the point of state-of-the-art equipment, there is currently a void in available technical information needed for use with this process. The type of information sought after concerns the area of electrode/workpiece combinations. This is in reference to the task of choosing the correct electrode material for the specific workpiece material encountered. A brief description of the EDM process will help in understanding the electrode/workpiece relationship.

Dependency between removal characteristics and defined measurement categories of pellets

NASA Astrophysics Data System (ADS)

Vogt, C.; Rohrbacher, M.; Rascher, R.; Sinzinger, S.

2015-09-01

Optical surfaces are usually machined by grinding and polishing. To achieve short polishing times it is necessary to grind with best possible form accuracy and with low sub surface damages. This is possible by using very fine grained grinding tools for the finishing process. These however often show time dependent properties regarding cutting ability in conjunction with tool wear. Fine grinding tools in the optics are often pellet-tools. For a successful grinding process the tools must show a constant self-sharpening performance. A constant, at least predictable wear and cutting behavior is crucial for a deterministic machining. This work describes a method to determine the characteristics of pellet grinding tools by tests conducted with a single pellet. We investigate the determination of the effective material removal rate and the derivation of the G-ratio. Especially the change from the newly dressed via the quasi-stationary to the worn status of the tool is described. By recording the achieved roughness with the single pellet it is possible to derive the roughness expect from a series pellet tool made of pellets with the same specification. From the results of these tests the usability of a pellet grinding tool for a specific grinding task can be determined without testing a comparably expensive serial tool. The results are verified by a production test with a serial tool under series conditions. The collected data can be stored and used in an appropriate data base for tool characteristics and be combined with useful applications.

Tool life and cutting speed for the maximum productivity at the drilling of the stainless steel X22CrMoV12-1

NASA Astrophysics Data System (ADS)

Vlase, A.; Blăjină, O.; Iacob, M.; Darie, V.

2015-11-01

Two addressed issues in the research regarding the cutting machinability, establishing of the optimum cutting processing conditions and the optimum cutting regime, do not yet have sufficient data for solving. For this reason, in the paper it is proposed the optimization of the tool life and the cutting speed at the drilling of a certain stainless steel in terms of the maximum productivity. For this purpose, a nonlinear programming mathematical model to maximize the productivity at the drilling of the steel is developed in the paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the numerical mathematical model. Using this proposed model allows increasing the accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The results presented in this paper can be used in the production activity, in order to increase the productivity of the stainless steels machining. Also new research directions for the specialists in this interested field may come off from this paper.

Effect of cutting parameters on surface finish and machinability of graphite reinforced Al-8011 matrix composite

NASA Astrophysics Data System (ADS)

Anil, K. C.; Vikas, M. G.; Shanmukha Teja, B.; Sreenivas Rao, K. V.

2017-04-01

Many materials such as alloys, composites find their applications on the basis of machinability, cost and availability. In the present work, graphite (Grp) reinforced Aluminium 8011 is synthesized by convention stir casting process and Surface finish & machinability of prepared composite is examined by using lathe tool dynamometer attached with BANKA Lathe by varying the machining parameters like spindle speed, Depth of cut and Feed rate in 3 levels. Also, Roughness Average (Ra) of machined surfaces is measured by using Surface Roughness Tester (Mitutoyo SJ201). From the studies it is cleared that mechanical properties of a composites increases with addition of Grp and The cutting force were decreased with the reinforcement percentage and thus increases the machinability of composites and also results in increased surface finish.

Ductile-regime turning of germanium and silicon

NASA Technical Reports Server (NTRS)

Blake, Peter N.; Scattergood, Ronald O.

1989-01-01

Single-point diamond turning of silicon and germanium was investigated in order to clarify the role of cutting depth in coaxing a ductile chip formation in normally brittle substances. Experiments based on the rapid withdrawal of the tool from the workpiece have shown that microfracture damage is a function of the effective depth of cut (as opposed to the nominal cutting depth). In essence, damage created by the leading edge of the tool is removed several revolutions later by lower sections of the tool edge, where the effective cutting depth is less. It appears that a truly ductile cutting response can be achieved only when the effective cutting depth, or critical chip thickness, is less than about 20 nm. Factors such as tool rake angle are significant in that they will affect the actual value of the critical chip thickness for transition from brittle to ductile response. It is concluded that the critical chip thickness is an excellent parameter for measuring the effects of machining conditions on the ductility of the cut and for designing tool-workpiece geometry in both turning and grinding.

Ultrasonic/Sonic Rotary-Hammer Drills

NASA Technical Reports Server (NTRS)

Badescu, Mircea; Sherrit, Stewart; Bar-Cohen, Yoseph; Bao, Xiaoqi; Kassab, Steve

2010-01-01

Ultrasonic/sonic rotary-hammer drill (USRoHD) is a recent addition to the collection of apparatuses based on ultrasonic/sonic drill corer (USDC). As described below, the USRoHD has several features, not present in a basic USDC, that increase efficiency and provide some redundancy against partial failure. USDCs and related apparatuses were conceived for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. They have been described in numerous previous NASA Tech Briefs articles. To recapitulate: A USDC can be characterized as a lightweight, lowpower, piezoelectrically driven jackhammer in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. A basic USDC includes a piezoelectric stack, an ultrasonic transducer horn connected to the stack, a free mass ( free in the sense that it can bounce axially a short distance between hard stops on the horn and the bit), and a tool bit. The piezoelectric stack creates ultrasonic vibrations that are mechanically amplified by the horn. The bouncing of the free mass between the hard stops generates the sonic vibrations. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, little applied axial force is needed to make the apparatus advance into the material of interest. There are numerous potential applications for USDCs and related apparatuses in geological exploration on Earth and on remote planets. In early USDC experiments, it was observed that accumulation of cuttings in a drilled hole causes the rate of penetration of the USDC to decrease steeply with depth, and that the rate of penetration can be increased by removing the cuttings. The USRoHD concept provides for removal of cuttings in the same manner as that of a twist drill: An USRoHD includes a USDC and a motor with gearhead (see figure). The USDC provides the bit hammering and the motor provides the bit rotation. Like a twist drill bit, the shank of the tool bit of the USRoHD is fluted. As in the operation of a twist drill, the rotation of the fluted drill bit removes cuttings from the drilled hole. The USRoHD tool bit is tipped with a replaceable crown having cutting teeth on its front surface. The teeth are shaped to promote fracturing of the rock face through a combination of hammering and rotation of the tool bit. Helical channels on the outer cylindrical surface of the crown serve as a continuation of the fluted surface of the shank, helping to remove cuttings. In the event of a failure of the USDC, the USRoHD can continue to operate with reduced efficiency as a twist drill. Similarly, in the event of a failure of the gearmotor, the USRoHD can continue to operate with reduced efficiency as a USDC.

A new heat transfer analysis in machining based on two steps of 3D finite element modelling and experimental validation

NASA Astrophysics Data System (ADS)

Haddag, B.; Kagnaya, T.; Nouari, M.; Cutard, T.

2013-01-01

Modelling machining operations allows estimating cutting parameters which are difficult to obtain experimentally and in particular, include quantities characterizing the tool-workpiece interface. Temperature is one of these quantities which has an impact on the tool wear, thus its estimation is important. This study deals with a new modelling strategy, based on two steps of calculation, for analysis of the heat transfer into the cutting tool. Unlike the classical methods, considering only the cutting tool with application of an approximate heat flux at the cutting face, estimated from experimental data (e.g. measured cutting force, cutting power), the proposed approach consists of two successive 3D Finite Element calculations and fully independent on the experimental measurements; only the definition of the behaviour of the tool-workpiece couple is necessary. The first one is a 3D thermomechanical modelling of the chip formation process, which allows estimating cutting forces, chip morphology and its flow direction. The second calculation is a 3D thermal modelling of the heat diffusion into the cutting tool, by using an adequate thermal loading (applied uniform or non-uniform heat flux). This loading is estimated using some quantities obtained from the first step calculation, such as contact pressure, sliding velocity distributions and contact area. Comparisons in one hand between experimental data and the first calculation and at the other hand between measured temperatures with embedded thermocouples and the second calculation show a good agreement in terms of cutting forces, chip morphology and cutting temperature.

Proposing a Framework to Assess Internet Usage in University Education: An Empirical Investigation from a Student's Perspective

ERIC Educational Resources Information Center

Cheung, Waiman; Huang, Wayne

2005-01-01

University administrators are continuously investing in Information Technology (IT) to support learning and help deal with educational budget cuts. Instructors are increasingly making their teaching materials available on the Internet. While administrators and instructors would like to make the Internet an effective educational tool, they need to…

Experimental investigations on cryogenic cooling by liquid nitrogen in the end milling of hardened steel

NASA Astrophysics Data System (ADS)

Ravi, S.; Pradeep Kumar, M.

2011-09-01

Milling of hardened steel generates excessive heat during the chip formation process, which increases the temperature of cutting tool and accelerates tool wear. Application of conventional cutting fluid in milling process may not effectively control the heat generation also it has inherent health and environmental problems. To minimize health hazard and environmental problems caused by using conventional cutting fluid, a cryogenic cooling set up is developed to cool tool-chip interface using liquid nitrogen (LN 2). This paper presents results on the effect of LN 2 as a coolant on machinability of hardened AISI H13 tool steel for varying cutting speed in the range of 75-125 m/min during end milling with PVD TiAlN coated carbide inserts at a constant feed rate. The results show that machining with LN 2 lowers cutting temperature, tool flank wear, surface roughness and cutting forces as compared with dry and wet machining. With LN 2 cooling, it has been found that the cutting temperature was reduced by 57-60% and 37-42%; the tool flank wear was reduced by 29-34% and 10-12%; the surface roughness was decreased by 33-40% and 25-29% compared to dry and wet machining. The cutting forces also decreased moderately compared to dry and wet machining. This can be attributed to the fact that LN 2 machining provides better cooling and lubrication through substantial reduction in the cutting zone temperature.

A review on ductile mode cutting of brittle materials

NASA Astrophysics Data System (ADS)

Antwi, Elijah Kwabena; Liu, Kui; Wang, Hao

2018-06-01

Brittle materials have been widely employed for industrial applications due to their excellent mechanical, optical, physical and chemical properties. But obtaining smooth and damage-free surface on brittle materials by traditional machining methods like grinding, lapping and polishing is very costly and extremely time consuming. Ductile mode cutting is a very promising way to achieve high quality and crack-free surfaces of brittle materials. Thus the study of ductile mode cutting of brittle materials has been attracting more and more efforts. This paper provides an overview of ductile mode cutting of brittle materials including ductile nature and plasticity of brittle materials, cutting mechanism, cutting characteristics, molecular dynamic simulation, critical undeformed chip thickness, brittle-ductile transition, subsurface damage, as well as a detailed discussion of ductile mode cutting enhancement. It is believed that ductile mode cutting of brittle materials could be achieved when both crack-free and no subsurface damage are obtained simultaneously.

Thermal modelling of cooling tool cutting when milling by electrical analogy

NASA Astrophysics Data System (ADS)

Benabid, F.; Arrouf, M.; Assas, M.; Benmoussa, H.

2010-06-01

Measurement temperatures by (some devises) are applied immediately after shut-down and may be corrected for the temperature drop that occurs in the interval between shut-down and measurement. This paper presents a new procedure for thermal modelling of the tool cutting used just after machining; when the tool is out off the chip in order to extrapolate the cutting temperature from the temperature measured when the tool is at stand still. A fin approximation is made in enhancing heat loss (by conduction and convection) to air stream is used. In the modelling we introduce an equivalent thermal network to estimate the cutting temperature as a function of specific energy. In another hand, a local modified element lumped conduction equation is used to predict the temperature gradient with time when the tool is being cooled, with initial and boundary conditions. These predictions provide a detailed view of the global heat transfer coefficient as a function of cutting speed because the heat loss for the tool in air stream is an order of magnitude larger than in normal environment. Finally we deduct the cutting temperature by inverse method.

Operation Reliability Assessment for Cutting Tools by Applying a Proportional Covariate Model to Condition Monitoring Information

PubMed Central

Cai, Gaigai; Chen, Xuefeng; Li, Bing; Chen, Baojia; He, Zhengjia

2012-01-01

The reliability of cutting tools is critical to machining precision and production efficiency. The conventional statistic-based reliability assessment method aims at providing a general and overall estimation of reliability for a large population of identical units under given and fixed conditions. However, it has limited effectiveness in depicting the operational characteristics of a cutting tool. To overcome this limitation, this paper proposes an approach to assess the operation reliability of cutting tools. A proportional covariate model is introduced to construct the relationship between operation reliability and condition monitoring information. The wavelet packet transform and an improved distance evaluation technique are used to extract sensitive features from vibration signals, and a covariate function is constructed based on the proportional covariate model. Ultimately, the failure rate function of the cutting tool being assessed is calculated using the baseline covariate function obtained from a small sample of historical data. Experimental results and a comparative study show that the proposed method is effective for assessing the operation reliability of cutting tools. PMID:23201980

Advances in lenticular lens arrays for visual display

NASA Astrophysics Data System (ADS)

Johnson, R. Barry; Jacobsen, Gary A.

2005-08-01

Lenticular lens arrays are widely used in the printed display industry and in specialized applications of electronic displays. In general, lenticular arrays can create from interlaced printed images such visual effects as 3-D, animation, flips, morph, zoom, or various combinations. The use of these typically cylindrical lens arrays for this purpose began in the late 1920's. The lenses comprise a front surface having a spherical crosssection and a flat rear surface upon where the material to be displayed is proximately located. The principal limitation to the resultant image quality for current technology lenticular lenses is spherical aberration. This limitation causes the lenticular lens arrays to be generally thick (0.5 mm) and not easily wrapped around such items as cans or bottles. The objectives of this research effort were to develop a realistic analytical model, to significantly improve the image quality, to develop the tooling necessary to fabricate lenticular lens array extrusion cylinders, and to develop enhanced fabrication technology for the extrusion cylinder. It was determined that the most viable cross-sectional shape for the lenticular lenses is elliptical. This shape dramatically improves the image quality. The relationship between the lens radius, conic constant, material refractive index, and thickness will be discussed. A significant challenge was to fabricate a diamond-cutting tool having the proper elliptical shape. Both true elliptical and pseudo-elliptical diamond tools were designed and fabricated. The plastic sheets extruded can be quite thin (< 0.25 mm) and, consequently, can be wrapped around cans and the like. Fabrication of the lenticular engraved extrusion cylinder required remarkable development considering the large physical size and weight of the cylinder, and the tight mechanical tolerances associated with the lenticular lens molds cut into the cylinder's surface. The development of the cutting tool and the lenticular engraved extrusion cylinder will be presented in addition to an illustrative comparison of current lenticular technology and the new technology. Three U.S. patents have been issued as a consequence of this research effort.

Condition monitoring of turning process using infrared thermography technique - An experimental approach

NASA Astrophysics Data System (ADS)

Prasad, Balla Srinivasa; Prabha, K. Aruna; Kumar, P. V. S. Ganesh

2017-03-01

In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated. In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.

Comparative Investigation on Tool Wear during End Milling of AISI H13 Steel with Different Tool Path Strategies

NASA Astrophysics Data System (ADS)

Adesta, Erry Yulian T.; Riza, Muhammad; Avicena

2018-03-01

Tool wear prediction plays a significant role in machining industry for proper planning and control machining parameters and optimization of cutting conditions. This paper aims to investigate the effect of tool path strategies that are contour-in and zigzag tool path strategies applied on tool wear during pocket milling process. The experiments were carried out on CNC vertical machining centre by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. In an experiment with three factors at three levels, Response Surface Method (RSM) design of experiment with a standard called Central Composite Design (CCD) was employed. Results obtained indicate that tool wear increases significantly at higher range of feed per tooth compared to cutting speed and depth of cut. This result of this experimental work is then proven statistically by developing empirical model. The prediction model for the response variable of tool wear for contour-in strategy developed in this research shows a good agreement with experimental work.

Stability analysis of multipoint tool equipped with metal cutting ceramics

NASA Astrophysics Data System (ADS)

Maksarov, V. V.; Khalimonenko, A. D.; Matrenichev, K. G.

2017-10-01

The article highlights the issues of determining the stability of the cutting process by a multipoint cutting tool equipped with cutting ceramics. There were some recommendations offered on the choice of parameters of replaceable cutting ceramic plates for milling based of the conducted researches. Ceramic plates for milling are proposed to be selected on the basis of value of their electrical volume resistivity.

Technological support of tool wear resistant qualities and cost saving of process of planetary grinding of flat parts

NASA Astrophysics Data System (ADS)

Ivanova, T. N.; Lyupa, D. C.; Revenko, N. F.; Berkutova, T. A.; Silivanova, O. A.

2018-03-01

A lot of factors varied in time lead to instability of the grinding process. Besides, the method of grinding influences significantly the productivity and quality of processing. In this regard a creation of processes of intensive defect-free grinding on the basis of new constructive and technology solutions represents the scientific problem which is of great importance. One of such solutions is application of planetary face grinding which allows simultaneously changing the kinematics of movement, implementing discontinuous grinding. The distinctive features of such grinding are decreasing the heat release rate in a contact zone; ensuring intermittence of the process with a solid grinding wheel; reverse grinding; cutting by different edges of an abrasive grain; stabilization of working parameters of a grinding wheel; ensuring work of a grinding wheel in a self-sharpening mode. The design of the planetary grinding tool was developed for plane surface processing for implementation of the specified distinctive features of planetary grinding. The kinematics of shaping a surface by flat face diamond grinding has been investigated; manufacturing capabilities of planetary face grinding have been revealed, and ways of improvement of quality and productivity have been offered. The algorithm and the program to define the motion path of a grain depending on the given set of grinding factors were received. Optimization of the process of face diamond grinding using the planetary grinding device has been confirmed with the developed program and techniques to choose cutting conditions of planetary grinding and characteristics of grinding wheels for processing different materials. While studying the process of planetary grinding, special attention was paid to the research how processing conditions influence microgeometry of the processed surface made of steel 4X5M (Russian State Standard (GOST)). As a result of the executed research, it was established that surface roughness parameter Ra during the processing using the planetary grinding device is 35 - 40% less than when using the tool with the solid cutting surface. This phenomenon can be accounted for more uniform work of the cutting grains of the planetary grinding tool as the number of meetings of diamond grains with the surface being processed increases. At the same time, it should be noted that during the planetary grinding more intensive smoothing of tops of microroughnesses is observed that provides the creation of steadier cutting shape. The given method of calculation of cost value of grinding operation allows solving various manufacturing problems: to compare cost value of grinding different materials, grinding wheels of different parameters; to define the optimum grinding conditions.

Online machining error estimation method of numerical control gear grinding machine tool based on data analysis of internal sensors

NASA Astrophysics Data System (ADS)

Zhao, Fei; Zhang, Chi; Yang, Guilin; Chen, Chinyin

2016-12-01

This paper presents an online estimation method of cutting error by analyzing of internal sensor readings. The internal sensors of numerical control (NC) machine tool are selected to avoid installation problem. The estimation mathematic model of cutting error was proposed to compute the relative position of cutting point and tool center point (TCP) from internal sensor readings based on cutting theory of gear. In order to verify the effectiveness of the proposed model, it was simulated and experimented in gear generating grinding process. The cutting error of gear was estimated and the factors which induce cutting error were analyzed. The simulation and experiments verify that the proposed approach is an efficient way to estimate the cutting error of work-piece during machining process.

Non-Poissonian photon statistics from macroscopic photon cutting materials.

PubMed

de Jong, Mathijs; Meijerink, Andries; Rabouw, Freddy T

2017-05-24

In optical materials energy is usually extracted only from the lowest excited state, resulting in fundamental energy-efficiency limits such as the Shockley-Queisser limit for single-junction solar cells. Photon-cutting materials provide a way around such limits by absorbing high-energy photons and 'cutting' them into multiple low-energy excitations that can subsequently be extracted. The occurrence of photon cutting or quantum cutting has been demonstrated in a variety of materials, including semiconductor quantum dots, lanthanides and organic dyes. Here we show that photon cutting results in bunched photon emission on the timescale of the excited-state lifetime, even when observing a macroscopic number of optical centres. Our theoretical derivation matches well with experimental data on NaLaF 4 :Pr 3+ , a material that can cut deep-ultraviolet photons into two visible photons. This signature of photon cutting can be used to identify and characterize new photon-cutting materials unambiguously.

Surface roughness model based on force sensors for the prediction of the tool wear.

PubMed

de Agustina, Beatriz; Rubio, Eva María; Sebastián, Miguel Ángel

2014-04-04

In this study, a methodology has been developed with the objective of evaluating the surface roughness obtained during turning processes by measuring the signals detected by a force sensor under the same cutting conditions. In this way, the surface quality achieved along the process is correlated to several parameters of the cutting forces (thrust forces, feed forces and cutting forces), so the effect that the tool wear causes on the surface roughness is evaluated. In a first step, the best cutting conditions (cutting parameters and radius of tool) for a certain quality surface requirement were found for pieces of UNS A97075. Next, with this selection a model of surface roughness based on the cutting forces was developed for different states of wear that simulate the behaviour of the tool throughout its life. The validation of this model reveals that it was effective for approximately 70% of the surface roughness values obtained.

Application of gas-fluid atomization technology in ultrosonic vibration cutting titanium alloy workpiece

NASA Astrophysics Data System (ADS)

Zhou, Zhimin; Zhang, Yuangliang; Li, Xiaoyan; Sun, Baoyuan

2009-11-01

To further improve machined surface quality of diamond cutting titanium workpiece and reduce diamond tool wear, it puts forward a kind of machining technology with mixture of carbon dioxide gas, water and vegetable oil atomized mist as cooling media in the paper. The cooling media is sprayed to cutting area through gas-liquid atomizer device to achieve purpose of cooling, lubricating, and protecting diamond tool. Experiments indicate that carbon dioxide gas can touch cutting surface more adequately through using gas-liquid atomization technology, which makes iron atoms of cutting surface cause a chemical reaction directly with carbon in carbon dioxide gas and reduce graphitizing degree of diamond tool. Thus, this technology of using gas-liquid atomization and ultrasonic vibration together for cutting Titanium Alloy is able to improve machined surface quality of workpiece and slow of diamond tool wear.

Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

NASA Astrophysics Data System (ADS)

Okokpujie, Imhade Princess; Ikumapayi, Omolayo M.; Okonkwo, Ugochukwu C.; Salawu, Enesi Y.; Afolalu, Sunday A.; Dirisu, Joseph O.; Nwoke, Obinna N.; Ajayi, Oluseyi O.

2017-12-01

In recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Tool wear analysis during duplex stainless steel trochoidal milling

NASA Astrophysics Data System (ADS)

Amaro, Paulo; Ferreira, Pedro; Simões, Fernando

2018-05-01

In this study a tool with interchangeable inserts of sintered carbides coated with AlTiN were used to mill a duplex stainless steel with trochoidal strategies. Cutting speed range from 120 to 300 m/min were used and t he evaluation of tool deterioration and tool life was made according international standard ISO 8688-1. It was observed a progressive development of a flank wear and a cumulative cyclic process of localized adhesion of the chip to the cutting edge, followed by chipping, loss of the coating and substrate exposure. The tool life reached a maximum of 35 min. for cutting speed of 120 m/min. However, it was possible to maintain a tool life of 20-25 minutes when the cutting speed was increased up to 240 m/min.

A Novel Mobile Testing Equipment for Rock Cuttability Assessment: Vertical Rock Cutting Rig (VRCR)

NASA Astrophysics Data System (ADS)

Yasar, Serdar; Yilmaz, Ali Osman

2017-04-01

In this study, a new mobile rock cutting testing apparatus was designed and produced for rock cuttability assessment called vertical rock cutting rig (VRCR) which was designed specially to fit into hydraulic press testing equipment which are available in almost every rock mechanics laboratory. Rock cutting trials were initiated just after the production of VRCR along with calibration of the measuring load cell with an external load cell to validate the recorded force data. Then, controlled rock cutting tests with both relieved and unrelieved cutting modes were implemented on five different volcanic rock samples with a standard simple-shaped wedge tool. Additionally, core cutting test which is an important approach for roadheader performance prediction was simulated with VRCR. Mini disc cutters and point attack tools were used for execution of experimental trials. Results clearly showed that rock cutting tests were successfully realized and measuring system is delicate to rock strength, cutting depth and other variables. Core cutting test was successfully simulated, and it was also shown that rock cutting tests with mini disc cutters and point attack tools are also successful with VRCR.

An application of eddy current damping effect on single point diamond turning of titanium alloys

NASA Astrophysics Data System (ADS)

Yip, W. S.; To, S.

2017-11-01

Titanium alloys Ti6Al4V (TC4) have been popularly applied in many industries. They have superior material properties including an excellent strength-to-weight ratio and corrosion resistance. However, they are regarded as difficult to cut materials; serious tool wear, a high level of cutting vibration and low surface integrity are always involved in machining processes especially in ultra-precision machining (UPM). In this paper, a novel hybrid machining technology using an eddy current damping effect is firstly introduced in UPM to suppress machining vibration and improve the machining performance of titanium alloys. A magnetic field was superimposed on samples during single point diamond turning (SPDT) by exposing the samples in between two permanent magnets. When the titanium alloys were rotated within a magnetic field in the SPDT, an eddy current was generated through a stationary magnetic field inside the titanium alloys. An eddy current generated its own magnetic field with the opposite direction of the external magnetic field leading a repulsive force, compensating for the machining vibration induced by the turning process. The experimental results showed a remarkable improvement in cutting force variation, a significant reduction in adhesive tool wear and an extreme long chip formation in comparison to normal SPDT of titanium alloys, suggesting the enhancement of the machinability of titanium alloys using an eddy current damping effect. An eddy current damping effect was firstly introduced in the area of UPM to deliver the results of outstanding machining performance.

Study of Tool Wear Mechanisms and Mathematical Modeling of Flank Wear During Machining of Ti Alloy (Ti6Al4V)

NASA Astrophysics Data System (ADS)

Chetan; Narasimhulu, A.; Ghosh, S.; Rao, P. V.

2015-07-01

Machinability of titanium is poor due to its low thermal conductivity and high chemical affinity. Lower thermal conductivity of titanium alloy is undesirable on the part of cutting tool causing extensive tool wear. The main task of this work is to predict the various wear mechanisms involved during machining of Ti alloy (Ti6Al4V) and to formulate an analytical mathematical tool wear model for the same. It has been found from various experiments that adhesive and diffusion wear are the dominating wear during machining of Ti alloy with PVD coated tungsten carbide tool. It is also clear from the experiments that the tool wear increases with the increase in cutting parameters like speed, feed and depth of cut. The wear model was validated by carrying out dry machining of Ti alloy at suitable cutting conditions. It has been found that the wear model is able to predict the flank wear suitably under gentle cutting conditions.

CUTTING AND WEDGING JACKET REMOVER

DOEpatents

Freedman, M.; Raynor, S.

1959-04-01

A tool is presented for stripping cladded jackets from fissionable fuel elements. The tool is a tube which fits closely around the jacket and which has two cutting edges at opposite sides of one end. These cutting edges are adjusted to penetrate only the jacket so that by moving the edges downward the jacket is cut into two pieces.

Experimental analysis of Nd-YAG laser cutting of sheet materials - A review

NASA Astrophysics Data System (ADS)

Sharma, Amit; Yadava, Vinod

2018-01-01

Cutting of sheet material is considered as an important process due to its relevance among products of everyday life such as aircrafts, ships, cars, furniture etc. Among various sheet cutting processes (ASCPs), laser beam cutting is one of the most capable ASCP to create complex geometries with stringent design requirements in difficult-to-cut sheet materials. Based on the recent research work in the area of sheet cutting, it is found that the Nd-YAG laser is used for cutting of sheet material in general and reflective sheet material in particular. This paper reviews the experimental analysis of Nd-YAG laser cutting process, carried out to study the influence of laser cutting parameters on the process performance index. The significance of experimental modeling and different optimization approaches employed by various researchers has also been discussed in this study.

Tool post modification allows easy turret lathe cutting-tool alignment

NASA Technical Reports Server (NTRS)

Fouts, L.

1966-01-01

Modified tool holder and tool post permit alignment of turret lathe cutting tools on the center of the spindle. The tool is aligned with the spindle by the holder which is kept in position by a hydraulic lock in feature of the tool post. The tool post is used on horizontal and vertical turret lathes and other engine lathes.

Cutting and drilling of carbon fiber reinforced plastics (CFRP) by 70W short pulse nanosecond laser

NASA Astrophysics Data System (ADS)

Jaeschke, Peter; Stolberg, Klaus; Bastick, Stefan; Ziolkowski, Ewa; Roehner, Markus; Suttmann, Oliver; Overmeyer, Ludger

2014-02-01

Continuous carbon fibre reinforced plastics (CFRP) are recognized as having a significant lightweight construction potential for a wide variety of industrial applications. However, a today`s barrier for a comprehensive dissemination of CFRP structures is the lack of economic, quick and reliable manufacture processes, e.g. the cutting and drilling steps. In this paper, the capability of using pulsed disk lasers in CFRP machining is discussed. In CFRP processing with NIR lasers, carbon fibers show excellent optical absorption and heat dissipation, contrary to the plastics matrix. Therefore heat dissipation away from the laser focus into the material is driven by heat conduction of the fibres. The matrix is heated indirectly by heat transfer from the fibres. To cut CFRP, it is required to reach the melting temperature for thermoplastic matrix materials or the disintegration temperature for thermoset systems as well as the sublimation temperature of the reinforcing fibers simultaneously. One solution for this problem is to use short pulse nanosecond lasers. We have investigated CFRP cutting and drilling with such a laser (max. 7 mJ @ 10 kHz, 30 ns). This laser offers the opportunity of wide range parameter tuning for systematic process optimization. By applying drilling and cutting operations based on galvanometer scanning techniques in multi-cycle mode, excellent surface and edge characteristics in terms of delamination-free and intact fiber-matrix interface were achieved. The results indicate that nanosecond disk laser machining could consequently be a suitable tool for the automotive and aircraft industry for cutting and drilling steps.

Construction safety in DOE. Part 1, Students guide

DOE Office of Scientific and Technical Information (OSTI.GOV)

Handwerk, E C

This report is the first part of a compilation of safety standards for construction activities on DOE facilities. This report covers the following areas: general safety and health provisions; occupational health and environmental control/haz mat; personal protective equipment; fire protection and prevention; signs, signals, and barricades; materials handling, storage, use, and disposal; hand and power tools; welding and cutting; electrical; and scaffolding.

Software Cuts Homebuilding Costs, Increases Energy Efficiency

NASA Technical Reports Server (NTRS)

2015-01-01

To sort out the best combinations of technologies for a crewed mission to Mars, NASA Headquarters awarded grants to MIT's Department of Aeronautics and Astronautics to develop an algorithm-based software tool that highlights the most reliable and cost-effective options. Utilizing the software, Professor Edward Crawley founded Cambridge, Massachussetts-based Ekotrope, which helps homebuilders choose cost- and energy-efficient floor plans and materials.

Regarding to the Variance Analysis of Regression Equation of the Surface Roughness obtained by End Milling process of 7136 Aluminium Alloy

NASA Astrophysics Data System (ADS)

POP, A. B.; ȚÎȚU, M. A.

2016-11-01

In the metal cutting process, surface quality is intrinsically related to the cutting parameters and to the cutting tool geometry. At the same time, metal cutting processes are closely related to the machining costs. The purpose of this paper is to reduce manufacturing costs and processing time. A study was made, based on the mathematical modelling of the average of the absolute value deviation (Ra) resulting from the end milling process on 7136 aluminium alloy, depending on cutting process parameters. The novel element brought by this paper is the 7136 aluminium alloy type, chosen to conduct the experiments, which is a material developed and patented by Universal Alloy Corporation. This aluminium alloy is used in the aircraft industry to make parts from extruded profiles, and it has not been studied for the proposed research direction. Based on this research, a mathematical model of surface roughness Ra was established according to the cutting parameters studied in a set experimental field. A regression analysis was performed, which identified the quantitative relationships between cutting parameters and the surface roughness. Using the variance analysis ANOVA, the degree of confidence for the achieved results by the regression equation was determined, and the suitability of this equation at every point of the experimental field.

Tool Enlarges Hard-to-Reach Holes

NASA Technical Reports Server (NTRS)

Geddes, J. P.

1984-01-01

Tool centers itself and cuts precise depth. Tool consists of crosscut carbide bur; sleeve that serves as depth stop and pilot; length of flexible, strong piano wire; and standard drive socket. Parts brazed together. Piano wire transmits torque and axial force to cutting tool.

Application of Taguchi Method for Analyzing Factors Affecting the Performance of Coated Carbide Tool When Turning FCD700 in Dry Cutting Condition

NASA Astrophysics Data System (ADS)

Ghani, Jaharah A.; Mohd Rodzi, Mohd Nor Azmi; Zaki Nuawi, Mohd; Othman, Kamal; Rahman, Mohd. Nizam Ab.; Haron, Che Hassan Che; Deros, Baba Md

2011-01-01

Machining is one of the most important manufacturing processes in these modern industries especially for finishing an automotive component after the primary manufacturing processes such as casting and forging. In this study the turning parameters of dry cutting environment (without air, normal air and chilled air), various cutting speed, and feed rate are evaluated using a Taguchi optimization methodology. An orthogonal array L27 (313), signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are employed to analyze the effect of these turning parameters on the performance of a coated carbide tool. The results show that the tool life is affected by the cutting speed, feed rate and cutting environment with contribution of 38%, 32% and 27% respectively. Whereas for the surface roughness, the feed rate is significantly controlled the machined surface produced by 77%, followed by the cutting environment of 19%. The cutting speed is found insignificant in controlling the machined surface produced. The study shows that the dry cutting environment factor should be considered in order to produce longer tool life as well as for obtaining a good machined surface.

New developments in surface technology and prototyping

NASA Astrophysics Data System (ADS)

Himmer, Thomas; Beyer, Eckhard

2003-03-01

Novel lightweight applications in the automotive and aircraft industries require advanced materials and techniques for surface protection as well as direct and rapid manufacturing of the related components and tools. The manufacturing processes presented in this paper are based on multiple additive and subtractive technologies such as laser cutting, laser welding, direct laser metal deposition, laser/plasma hybrid spraying technique or CNC milling. The process chain is similar to layer-based Rapid Prototyping Techniques. In the first step, the 3D CAD geometry is sliced into layers by a specially developed software. These slices are cut by high speed laser cutting and then joined together. In this way laminated tools or parts are built. To improve surface quality and to increase wear resistance a CNC machining center is used. The system consists of a CNC milling machine, in which a 3 kW Nd:YAG laser, a coaxial powder nozzle and a digitizing system are integrated. Using a new laser/plasma hybrid spraying technique, coatings can be deposited onto parts for surface protection. The layers show a low porosity and high adhesion strength, the thickness is up to 0.3 mm, and the lower effort for preliminary surface preparation reduces time and costs of the whole process.

Combination of Ultrasonic Vibration and Cryogenic Cooling for Cutting Performance Improvement of Inconel 718 Turning

NASA Astrophysics Data System (ADS)

Lin, S. Y.; Chung, C. T.; Cheng, Y. Y.

2011-01-01

The main objective of this study is to develop a thermo-elastic-plastic coupling model, based on a combination skill of ultrasonically assisted cutting and cryogenic cooling, under large deformation for Inconel 718 alloy machining process. The improvement extent on cutting performance and tool life promotion may be examined from this investigation. The critical value of the strain energy density of the workpiece will be utilized as the chip separation and the discontinuous chip segmentation criteria. The forced convection cooling and a hydrodynamic lubrication model will be considered and formulated in the model. Finite element method will be applied to create a complete numerical solution for this ultrasonic vibration cutting model. During the analysis, the cutting tool is incrementally advanced forward with superimposed ultrasonic vibration in a back and forth step-by-step manner, from an incipient stage of tool-workpiece engagement to a steady state of chip formation, a whole simulation of orthogonal cutting process under plane strain deformation is thus undertaken. High shear strength induces a fluctuation phenomenon of shear angle, high shear strain rate, variation of chip types and chip morphology, tool-chip contact length variation, the temperature distributions within the workpiece, chip and tool, periodic fluctuation in cutting forces can be determined from the developed model. A complete comparison of machining characteristics between some different combinations of ultrasonically assisted cutting and cryogenic cooling with conventional cutting operation can be acquired. Finally, the high-speed turning experiment for Inconel 718 alloy will be taken in the laboratory to validate the accuracy of the model, and the progressive flank wear, crater wear, notching and chipping of the tool edge can also be measured in the experiments.

Achieving Small Structures in Thin NiTi Sheets for Medical Applications with Water Jet and Micro Machining: A Comparison

NASA Astrophysics Data System (ADS)

Frotscher, M.; Kahleyss, F.; Simon, T.; Biermann, D.; Eggeler, G.

2011-07-01

NiTi shape memory alloys (SMA) are used for a variety of applications including medical implants and tools as well as actuators, making use of their unique properties. However, due to the hardness and strength, in combination with the high elasticity of the material, the machining of components can be challenging. The most common machining techniques used today are laser cutting and electrical discharge machining (EDM). In this study, we report on the machining of small structures into binary NiTi sheets, applying alternative processing methods being well-established for other metallic materials. Our results indicate that water jet machining and micro milling can be used to machine delicate structures, even in very thin NiTi sheets. Further work is required to optimize the cut quality and the machining speed in order to increase the cost-effectiveness and to make both methods more competitive.

Electrical contact tool set station

DOEpatents

Byers, M.E.

1988-02-22

An apparatus is provided for the precise setting to zero of electrically conductive cutting tools used in the machining of work pieces. An electrically conductive cylindrical pin, tapered at one end to a small flat, rests in a vee-shaped channel in a base so that its longitudinal axis is parallel to the longitudinal axis of the machine's spindle. Electronic apparatus is connected between the cylindrical pin and the electrically conductive cutting tool to produce a detectable signal when contact between tool and pin is made. The axes of the machine are set to zero by contact between the cutting tool and the sides, end or top of the cylindrical pin. Upon contact, an electrical circuit is completed, and the detectable signal is produced. The tool can then be set to zero for that axis. Should the tool contact the cylindrical pin with too much force, the cylindrical pin would be harmlessly dislodged from the vee-shaped channel, preventing damage either to the cutting tool or the cylindrical pin. 5 figs.

Pilot study of manual sugarcane harvesting using biomechanical analysis.

PubMed

Clementson, C L; Hansen, A C

2008-07-01

In many countries, sugar cane harvesting is a very labor-intensive activity in which workers usually become fatigued after manually cutting the cane for a few hours. They need frequent pauses for rest, and they experience sustained injuries from excessive stress on the joints and muscles of the body. The cutting tool and motion involved directly influence the stresses created. A cutting tool that has not been designed by taking into consideration occupational biomechanics can lead to unnecessary strains in the body's muscle system, resulting in injuries. The purpose of this research was to carry out a pilot study of the impact of two common manual sugarcane cutting tools and the cutting posture they induce on the body with the aid of biomechanics. The machete and the cutlass from South Africa and Guyana, respectively, were examined to determine the cutting forces. Using static strength prediction modeling, the body stress levels at the point of cut in the cutting motion were determined. The cutting postures of three subjects were contrasted, their extreme postures were identified, and suggestions were made to improve the ergonomics of the cutting activity. The results of this pilot study showed that the cutlass required less cutting force than the machete because of the slicing cut provided by the curved blade edge of the cutlass. However, the biomechanical analysis indicated that the bent blade of the machete required less flexion of the back and therefore was likely to cause less back fatigue and injury. An improved design of the sugarcane manual harvesting tool should incorporate the bend of the machete to reduce flexion and a curved cutting edge that provides a slicing cut.

Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel

NASA Astrophysics Data System (ADS)

Outeiro, José C.; Umbrello, Domenico; Pina, José C.; Rizzuti, Stefania

2007-05-01

Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, the uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.

Prediction Of Abrasive And Diffusive Tool Wear Mechanisms In Machining

NASA Astrophysics Data System (ADS)

Rizzuti, S.; Umbrello, D.

2011-01-01

Tool wear prediction is regarded as very important task in order to maximize tool performance, minimize cutting costs and improve the quality of workpiece in cutting. In this research work, an experimental campaign was carried out at the varying of cutting conditions with the aim to measure both crater and flank tool wear, during machining of an AISI 1045 with an uncoated carbide tool P40. Parallel a FEM-based analysis was developed in order to study the tool wear mechanisms, taking also into account the influence of the cutting conditions and the temperature reached on the tool surfaces. The results show that, when the temperature of the tool rake surface is lower than the activation temperature of the diffusive phenomenon, the wear rate can be estimated applying an abrasive model. In contrast, in the tool area where the temperature is higher than the diffusive activation temperature, the wear rate can be evaluated applying a diffusive model. Finally, for a temperature ranges within the above cited values an adopted abrasive-diffusive wear model furnished the possibility to correctly evaluate the tool wear phenomena.

Some aspects of precise laser machining - Part 2: Experimental

NASA Astrophysics Data System (ADS)

Grabowski, Marcin; Wyszynski, Dominik; Ostrowski, Robert

2018-05-01

The paper describes the role of laser beam polarization on quality of laser beam machined cutting tool edge. In micromachining the preparation of the cutting tools in play a key role on dimensional accuracy, sharpness and the quality of the cutting edges. In order to assure quality and dimensional accuracy of the cutting tool edge it is necessary to apply laser polarization control. In the research diode pumped Nd:YAG 532nm pulse laser was applied. Laser beam polarization used in the research was linear (horizontal, vertical). The goal of the carried out research was to describe impact of laser beam polarization on efficiency of the cutting process and quality of machined parts (edge, surface) made of polycrystalline diamond (PCD) and cubic boron nitride (cBN). Application of precise cutting tool in micromachining has significant impact on the minimum uncut chip thickness and quality of the parts. The research was carried within the INNOLOT program funded by the National Centre for Research and Development.

Surface Roughness Model Based on Force Sensors for the Prediction of the Tool Wear

PubMed Central

de Agustina, Beatriz; Rubio, Eva María; Sebastián, Miguel Ángel

2014-01-01

In this study, a methodology has been developed with the objective of evaluating the surface roughness obtained during turning processes by measuring the signals detected by a force sensor under the same cutting conditions. In this way, the surface quality achieved along the process is correlated to several parameters of the cutting forces (thrust forces, feed forces and cutting forces), so the effect that the tool wear causes on the surface roughness is evaluated. In a first step, the best cutting conditions (cutting parameters and radius of tool) for a certain quality surface requirement were found for pieces of UNS A97075. Next, with this selection a model of surface roughness based on the cutting forces was developed for different states of wear that simulate the behaviour of the tool throughout its life. The validation of this model reveals that it was effective for approximately 70% of the surface roughness values obtained. PMID:24714391

“Investigations on the machinability of Waspaloy under dry environment”

NASA Astrophysics Data System (ADS)

Deepu, J.; Kuppan, P.; SBalan, A. S.; Oyyaravelu, R.

2016-09-01

Nickel based superalloy, Waspaloy is extensively used in gas turbine, aerospace and automobile industries because of their unique combination of properties like high strength at elevated temperatures, resistance to chemical degradation and excellent wear resistance in many hostile environments. It is considered as one of the difficult to machine superalloy due to excessive tool wear and poor surface finish. The present paper is an attempt for removing cutting fluids from turning process of Waspaloy and to make the processes environmentally safe. For this purpose, the effect of machining parameters such as cutting speed and feed rate on the cutting force, cutting temperature, surface finish and tool wear were investigated barrier. Consequently, the strength and tool wear resistance and tool life increased significantly. Response Surface Methodology (RSM) has been used for developing and analyzing a mathematical model which describes the relationship between machining parameters and output variables. Subsequently ANOVA was used to check the adequacy of the regression model as well as each machining variables. The optimal cutting parameters were determined based on multi-response optimizations by composite desirability approach in order to minimize cutting force, average surface roughness and maximum flank wear. The results obtained from the experiments shown that machining of Waspaloy using coated carbide tool with special ranges of parameters, cutting fluid could be completely removed from machining process

Machine tool task force

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sutton, G.P.

1980-10-22

The Machine Tool Task Force (MTTF) is a multidisciplined team of international experts, whose mission was to investigate the state of the art of machine tool technology, to identify promising future directions of that technology for both the US government and private industry, and to disseminate the findings of its research in a conference and through the publication of a final report. MTTF was a two and one-half year effort that involved the participation of 122 experts in the specialized technologies of machine tools and in the management of machine tool operations. The scope of the MTTF was limited tomore » cutting-type or material-removal-type machine tools, because they represent the major share and value of all machine tools now installed or being built. The activities of the MTTF and the technical, commercial and economic signifiance of recommended activities for improving machine tool technology are discussed. (LCL)« less

Prediction of the wear and evolution of cutting tools in a carbide / titanium-aluminum-vanadium machining tribosystem by volumetric tool wear characterization and modeling

NASA Astrophysics Data System (ADS)

Kuttolamadom, Mathew Abraham

The objective of this research work is to create a comprehensive microstructural wear mechanism-based predictive model of tool wear in the tungsten carbide / Ti-6Al-4V machining tribosystem, and to develop a new topology characterization method for worn cutting tools in order to validate the model predictions. This is accomplished by blending first principle wear mechanism models using a weighting scheme derived from scanning electron microscopy (SEM) imaging and energy dispersive x-ray spectroscopy (EDS) analysis of tools worn under different operational conditions. In addition, the topology of worn tools is characterized through scanning by white light interferometry (WLI), and then application of an algorithm to stitch and solidify data sets to calculate the volume of the tool worn away. The methodology was to first combine and weight dominant microstructural wear mechanism models, to be able to effectively predict the tool volume worn away. Then, by developing a new metrology method for accurately quantifying the bulk-3D wear, the model-predicted wear was validated against worn tool volumes obtained from corresponding machining experiments. On analyzing worn crater faces using SEM/EDS, adhesion was found dominant at lower surface speeds, while dissolution wear dominated with increasing speeds -- this is in conformance with the lower relative surface speed requirement for micro welds to form and rupture, essentially defining the mechanical load limit of the tool material. It also conforms to the known dominance of high temperature-controlled wear mechanisms with increasing surface speed, which is known to exponentially increase temperatures especially when machining Ti-6Al-4V due to its low thermal conductivity. Thus, straight tungsten carbide wear when machining Ti-6Al-4V is mechanically-driven at low surface speeds and thermally-driven at high surface speeds. Further, at high surface speeds, craters were formed due to carbon diffusing to the tool surface and being carried away by the rubbing action of the chips -- this left behind a smooth crater surface predominantly of tungsten and cobalt as observed from EDS analysis. Also, at high surface speeds, carbon from the tool was found diffused into the adhered titanium layer to form a titanium carbide (TiC) boundary layer -- this was observed as instances of TiC build-up on the tool edge from EDS analysis. A complex wear mechanism interaction was thus observed, i.e., titanium adhered on top of an earlier worn out crater trough, additional carbon diffused into this adhered titanium layer to create a more stable boundary layer (which could limit diffusion-rates on saturation), and then all were further worn away by dissolution wear as temperatures increased. At low and medium feeds, notch discoloration was observed -- this was detected to be carbon from EDS analysis, suggesting that it was deposited from the edges of the passing chips. Mapping the dominant wear mechanisms showed the increasing dominance of dissolution wear relative to adhesion, with increasing grain size -- this is because a 13% larger sub-micron grain results in a larger surface area of cobalt exposed to chemical action. On the macro-scale, wear quantification through topology characterization elevated wear from a 1D to 3D concept. From investigation, a second order dependence of volumetric tool wear (VTW) and VTW rate with the material removal rate (MRR) emerged, suggesting that MRR is a more consistent wear-controlling factor instead of the traditionally used cutting speed. A predictive model for VTW was developed which showed its exponential dependence with workpiece stock volume removed. Also, both VTW and VTW rate were found to be dependent on the accumulated cumulative wear on the tool. Further, a ratio metric of stock material removed to tool volume lost is now possible as a tool efficiency quantifier and energy-based productivity parameter, which was found to inversely depend on MRR - this led to a more comprehensive tool wear definition based on cutting tool efficiency. (Abstract shortened by UMI.)

Cut marks on bone surfaces: influences on variation in the form of traces of ancient behaviour

PubMed Central

Braun, David R.; Pante, Michael; Archer, William

2016-01-01

Although we know that our lineage has been producing sharp-edged tools for over 2.6 Myr, our knowledge of what they were doing with these tools is far less complete. Studies of these sharp-edged stone tools show that they were most probably used as cutting implements. However, the only substantial evidence of this is the presence of cut marks on the bones of animals found in association with stone tools in ancient deposits. Numerous studies have aimed to quantify the frequency and placement of these marks. At present there is little consensus on the meaning of these marks and how the frequency relates to specific behaviours in the past. Here we investigate the possibility that mechanical properties associated with edges of stone tools as well as the properties of bones themselves may contribute to the overall morphology of these marks and ultimately their placement in the archaeological record. Standardized tests of rock mechanics (Young's modulus and Vickers hardness) indicate that the hardness of tool edges significantly affects cut-mark morphology. In addition, we show that indentation hardness of bones also impacts the overall morphology of cut marks. Our results show that rock type and bone portions influence the shape and prevalence of cut marks on animal bones. PMID:27274806

Orthogonal cutting of cancellous bone with application to the harvesting of bone autograft.

PubMed

Malak, Sharif F F; Anderson, Iain A

2008-07-01

Autogenous bone graft harvesting results in cell death within the graft and trauma at the donor site. The latter can be mitigated by using minimally invasive tools and techniques, while cell morbidity may be reduced by improving cutter design and cutting parameters. We have performed orthogonal cutting experiments on bovine cancellous bone samples, to gain a basic understanding of the cutting mechanism and to determine design guidelines for tooling. Measurements were performed at cutting speeds from 11.2 to 5000 mm/min, with tool rake angles of 23 degrees, 45 degrees and 60 degrees, and depths of cut in the range of 0.1-3.0 mm. Horizontal and vertical cutting forces were measured, and the chip formation process video recorded. Continuous chip formation was observed for rake angles of 45 degrees and 60 degrees , and depths of cut greater than 0.8 mm. Chip formation for depths of cut greater than 1.0 mm was accompanied by bone marrow extruding out of the free surfaces and away from the rake face. Specific cutting energies decreased with increasing rake angle, increasing depth of cut and increasing cutting speed. Our orthogonal cutting experiments showed that a rake angle of 60 degrees and a depth of cut of 1mm, will avoid excessive fragmentation, keep specific cutting energy low and promote bone marrow extrusion, which may be beneficial for cell survival. We demonstrate how drill bit clearance angle and feed rate can be calculated facilitating a 1mm depth of cut.

Analysis about diamond tool wear in nano-metric cutting of single crystal silicon using molecular dynamics method

NASA Astrophysics Data System (ADS)

Wang, Zhiguo; Liang, Yingchun; Chen, Mingjun; Tong, Zhen; Chen, Jiaxuan

2010-10-01

Tool wear not only changes its geometry accuracy and integrity, but also decrease machining precision and surface integrity of workpiece that affect using performance and service life of workpiece in ultra-precision machining. Scholars made a lot of experimental researches and stimulant analyses, but there is a great difference on the wear mechanism, especially on the nano-scale wear mechanism. In this paper, the three-dimensional simulation model is built to simulate nano-metric cutting of a single crystal silicon with a non-rigid right-angle diamond tool with 0 rake angle and 0 clearance angle by the molecular dynamics (MD) simulation approach, which is used to investigate the diamond tool wear during the nano-metric cutting process. A Tersoff potential is employed for the interaction between carbon-carbon atoms, silicon-silicon atoms and carbon-silicon atoms. The tool gets the high alternating shear stress, the tool wear firstly presents at the cutting edge where intension is low. At the corner the tool is splitted along the {1 1 1} crystal plane, which forms the tipping. The wear at the flank face is the structure transformation of diamond that the diamond structure transforms into the sheet graphite structure. Owing to the tool wear the cutting force increases.

The chemo-mechanical effect of cutting fluid on material removal in diamond scribing of silicon

NASA Astrophysics Data System (ADS)

Kumar, Arkadeep; Melkote, Shreyes N.

2017-07-01

The mechanical integrity of silicon wafers cut by diamond wire sawing depends on the damage (e.g., micro-cracks) caused by the cutting process. The damage type and extent depends on the material removal mode, i.e., ductile or brittle. This paper investigates the effect of cutting fluid on the mode of material removal in diamond scribing of single crystal silicon, which simulates the material removal process in diamond wire sawing of silicon wafers. We conducted scribing experiments with a diamond tipped indenter in the absence (dry) and in the presence of a water-based cutting fluid. We found that the cutting mode is more ductile when scribing in the presence of cutting fluid compared to dry scribing. We explain the experimental observations by the chemo-mechanical effect of the cutting fluid on silicon, which lowers its hardness and promotes ductile mode material removal.

Nd:YAG Pulsed Laser Assisted Machining of AMS 5708 Waspaloy Alloy

NASA Astrophysics Data System (ADS)

Sharifi, Zahra; Shoja-Razavi, Reza; Vafaei, Reza; Hashemi, Sayed Hamid

2018-03-01

Due to very high strenght, low thermal conductivity, and high work hardening rate, the machinability of nickel-based superalloys is poor at room temperature. Laser-assisted machining (LAM) can provide a better aspect of machining such alloys. Since the wavelength of Nd:YAG laser is about 1/10th of that of CO2 laser, absorption and heating efficiency of Nd:YAG laser is much higher on metals and especially superalloys. Transmission of Nd:YAG laser through fiber optics to the heating point on the workpiece is a simple task during machining. This makes the LAM process more convenient and practical than the CM process. In this study a model is introduced for LAM of waspaloy, and its machinability is evaluated in terms of ease of material removal. Also, a temperature generation model is introduced for the Nd:YAG laser beam. Furthemore, wear behavior of an uncoated tungsten carbide and the formed chips were compared during the LAM and the CM of waspolay. To study the wear mechanism, the worn cutting tool was studied via scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). The formed chips were also evaluated via SEM and optical microscopy. Based on the results, the optimum LAM conditions were obtained at a cutting speed of 24 m/min and a feed rate of 0.06 mm/rev when a 400 W laser mean power and 80 Hz frequency are applied. Under these conditions, the temperature ahead of the cutting tool edge on the surface of workpiece was estimated to be 524°C. In comparison with CM, a significant improvement in tool wear and a better chip morphology were achieved through LAM, and also specific cutting energy and surface roughness were reduced by 25 and 20%, respectively.

Generalized interactions using virtual tools within the spring framework: cutting

NASA Technical Reports Server (NTRS)

Montgomery, Kevin; Bruyns, Cynthia D.

2002-01-01

We present schemes for real-time generalized mesh cutting. Starting with the a basic example, we describe the details of implementing cutting on single and multiple surface objects as well as hybrid and volumetric meshes using virtual tools with single and multiple cutting surfaces. These methods have been implemented in a robust surgical simulation environment allowing us to model procedures ranging from animal dissection to cleft lip correction.

Highly Productive Tools For Turning And Milling

NASA Astrophysics Data System (ADS)

Vasilko, Karol

2015-12-01

Beside cutting speed, shift is another important parameter of machining. Its considerable influence is shown mainly in the workpiece machined surface microgeometry. In practice, mainly its combination with the radius of cutting tool tip rounding is used. Options to further increase machining productivity and machined surface quality are hidden in this approach. The paper presents variations of the design of productive cutting tools for lathe work and milling on the base of the use of the laws of the relationship among the highest reached uneveness of machined surface, tool tip radius and shift.

Material Choice for spindle of machine tools

NASA Astrophysics Data System (ADS)

Gouasmi, S.; Merzoug, B.; Abba, G.; Kherredine, L.

2012-02-01

The requirements of contemporary industry and the flashing development of modern sciences impose restrictions on the majority of the elements of machines; the resulting financial constraints can be satisfied by a better output of the production equipment. As for those concerning the design, the resistance and the correct operation of the product, these require the development of increasingly precise parts, therefore the use of increasingly powerful tools [5]. The precision of machining and the output of the machine tools are generally determined by the precision of rotation of the spindle, indeed, more this one is large more the dimensions to obtain are in the zone of tolerance and the defects of shape are minimized. During the development of the machine tool, the spindle which by definition is a rotating shaft receiving and transmitting to the work piece or the cutting tool the rotational movement, must be designed according to certain optimal parameters to be able to ensure the precision required. This study will be devoted to the choice of the material of the spindle fulfilling the imposed requirements of precision.

Monitoring of Surface Roughness in Aluminium Turning Process

NASA Astrophysics Data System (ADS)

Chaijareenont, Atitaya; Tangjitsitcharoen, Somkiat

2018-01-01

As the turning process is one of the most necessary process. The surface roughness has been considered for the quality of workpiece. There are many factors which affect the surface roughness. Hence, the objective of this research is to monitor the relation between the surface roughness and the cutting forces in aluminium turning process with a wide range of cutting conditions. The coated carbide tool and aluminium alloy (Al 6063) are used for this experiment. The cutting parameters are investigated to analyze the effects of them on the surface roughness which are the cutting speed, the feed rate, the tool nose radius and the depth of cut. In the case of this research, the dynamometer is installed in the turret of CNC turning machine to generate a signal while turning. The relation between dynamic cutting forces and the surface roughness profile is examined by applying the Fast Fourier Transform (FFT). The experimentally obtained results showed that the cutting force depends on the cutting condition. The surface roughness can be improved when increasing the cutting speed and the tool nose radius in contrast to the feed rate and the depth of cut. The relation between the cutting parameters and the surface roughness can be explained by the in-process cutting forces. It is understood that the in-process cutting forces are able to predict the surface roughness in the further research.

30 CFR 77.1002 - Box cuts; spoil material placement.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Box cuts; spoil material placement. 77.1002 Section 77.1002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE... COAL MINES Ground Control § 77.1002 Box cuts; spoil material placement. When box cuts are made...

30 CFR 77.1002 - Box cuts; spoil material placement.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Box cuts; spoil material placement. 77.1002 Section 77.1002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE... COAL MINES Ground Control § 77.1002 Box cuts; spoil material placement. When box cuts are made...

Mamdani-Fuzzy Modeling Approach for Quality Prediction of Non-Linear Laser Lathing Process

NASA Astrophysics Data System (ADS)

Sivaraos; Khalim, A. Z.; Salleh, M. S.; Sivakumar, D.; Kadirgama, K.

2018-03-01

Lathing is a process to fashioning stock materials into desired cylindrical shapes which usually performed by traditional lathe machine. But, the recent rapid advancements in engineering materials and precision demand gives a great challenge to the traditional method. The main drawback of conventional lathe is its mechanical contact which brings to the undesirable tool wear, heat affected zone, finishing, and dimensional accuracy especially taper quality in machining of stock with high length to diameter ratio. Therefore, a novel approach has been devised to investigate in transforming a 2D flatbed CO2 laser cutting machine into 3D laser lathing capability as an alternative solution. Three significant design parameters were selected for this experiment, namely cutting speed, spinning speed, and depth of cut. Total of 24 experiments were performed with eight (8) sequential runs where they were then replicated three (3) times. The experimental results were then used to establish Mamdani - Fuzzy predictive model where it yields the accuracy of more than 95%. Thus, the proposed Mamdani - Fuzzy modelling approach is found very much suitable and practical for quality prediction of non-linear laser lathing process for cylindrical stocks of 10mm diameter.

Experimental evaluation of tool run-out in micro milling

NASA Astrophysics Data System (ADS)

Attanasio, Aldo; Ceretti, Elisabetta

2018-05-01

This paper deals with micro milling cutting process focusing the attention on tool run-out measurement. In fact, among the effects of the scale reduction from macro to micro (i.e., size effects) tool run-out plays an important role. This research is aimed at developing an easy and reliable method to measure tool run-out in micro milling based on experimental tests and an analytical model. From an Industry 4.0 perspective this measuring strategy can be integrated into an adaptive system for controlling cutting forces, with the objective of improving the production quality, the process stability, reducing at the same time the tool wear and the machining costs. The proposed procedure estimates the tool run-out parameters from the tool diameter, the channel width, and the phase angle between the cutting edges. The cutting edge phase measurement is based on the force signal analysis. The developed procedure has been tested on data coming from micro milling experimental tests performed on a Ti6Al4V sample. The results showed that the developed procedure can be successfully used for tool run-out estimation.

Mechanisms and FEM Simulation of Chip Formation in Orthogonal Cutting In-Situ TiB2/7050Al MMC

PubMed Central

Wang, Wenhu; Jiang, Ruisong; Lin, Kunyang; Shao, Mingwei

2018-01-01

The in-situ TiB2/7050Al composite is a new kind of Al-based metal matrix composite (MMC) with super properties, such as low density, improved strength, and wear resistance. This paper, for a deep insight into its cutting performance, involves a study of the chip formation process and finite element simulation during orthogonal cutting in-situ TiB2/7050Al MMC. With chips, material properties, cutting forces, and tool geometry parameters, the Johnson–Cook (J–C) constitutive equation of in-situ TiB2/7050Al composite was established. Then, the cutting simulation model was established by applying the Abaqus–Explicit method, and the serrated chip, shear plane, strain rate, and temperature were analyzed. The experimental and simulation results showed that the obtained material’s constitutive equation was of high reliability, and the saw-tooth chips occurred commonly under either low or high cutting speed and small or large feed rate. From result analysis, it was found that the mechanisms of chip formation included plastic deformation, adiabatic shear, shearing slip, and crack extension. In addition, it was found that the existence of small, hard particles reduced the ductility of the MMC and resulted in segmental chips. PMID:29662047

Dental abrasion as a cutting process.

PubMed

Lucas, Peter W; Wagner, Mark; Al-Fadhalah, Khaled; Almusallam, Abdulwahab S; Michael, Shaji; Thai, Lidia A; Strait, David S; Swain, Michael V; van Casteren, Adam; Renno, Waleed M; Shekeban, Ali; Philip, Swapna M; Saji, Sreeja; Atkins, Anthony G

2016-06-06

A mammalian tooth is abraded when a sliding contact between a particle and the tooth surface leads to an immediate loss of tooth tissue. Over time, these contacts can lead to wear serious enough to impair the oral processing of food. Both anatomical and physiological mechanisms have evolved in mammals to try to prevent wear, indicating its evolutionary importance, but it is still an established survival threat. Here we consider that many wear marks result from a cutting action whereby the contacting tip(s) of such wear particles acts akin to a tool tip. Recent theoretical developments show that it is possible to estimate the toughness of abraded materials via cutting tests. Here, we report experiments intended to establish the wear resistance of enamel in terms of its toughness and how friction varies. Imaging via atomic force microscopy (AFM) was used to assess the damage involved. Damage ranged from pure plastic deformation to fracture with and without lateral microcracks. Grooves cut with a Berkovich diamond were the most consistent, suggesting that the toughness of enamel in cutting is 244 J m(-2), which is very high. Friction was higher in the presence of a polyphenolic compound, indicating that this could increase wear potential.

Machining of Silicon-Ribbon-Forming Dies

NASA Technical Reports Server (NTRS)

Menna, A. A.

1985-01-01

Carbon extension for dies used in forming silicon ribbon crystals machined precisely with help of special tool. Die extension has edges beveled toward narrow flats at top, with slot precisely oriented and centered between flats and bevels. Cutting tool assembled from standard angle cutter and circular saw or saws. Angle cutters cuts bevels while slot saw cuts slot between them. In alternative version, custom-ground edges or additional circular saws also cut flats simultaneously.

Effect of magneto rheological damper on tool vibration during hard turning

NASA Astrophysics Data System (ADS)

Paul, P. Sam; Varadarajan, A. S.

2012-12-01

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

Strength of inserts in titanium alloy machining

NASA Astrophysics Data System (ADS)

Kozlov, V.; Huang, Z.; Zhang, J.

2016-04-01

In this paper, a stressed state of a non-worn cutting wedge in a machined titanium alloy (Ti6Al2Mo2Cr) is analyzed. The distribution of contact loads on the face of a cutting tool was obtained experimentally with the use of a ‘split cutting tool’. Calculation of internal stresses in the indexable insert made from cemented carbide (WC8Co) was carried out with the help of ANSYS 14.0 software. Investigations showed that a small thickness of the cutting insert leads to extremely high compressive stresses near the cutting edge, stresses that exceed the ultimate compressive strength of cemented carbide. The face and the base of the insert experience high tensile stresses, which approach the ultimate tensile strength of cemented carbide and increase a probability of cutting insert destruction. If the thickness of the cutting insert is bigger than 5 mm, compressive stresses near the cutting edge decrease, and tensile stresses on the face and base decrease to zero. The dependences of the greatest normal and tangential stresses on thickness of the cutting insert were found. Abbreviation and symbols: m/s - meter per second (cutting speed v); mm/r - millimeter per revolution (feed rate f); MPa - mega Pascal (dimension of specific contact loads and stresses); γ - rake angle of the cutting tool [°] α - clearance angle of the sharp cutting tool [°].

Fundamental studies on a novel die concept for round-point shear-clinching

NASA Astrophysics Data System (ADS)

Hörhold, Réjane; Müller, Martin; Merklein, Marion; Meschut, Gerson

2016-10-01

A newly-developed round-point shear-clinching technology could increase the use of different materials like well formable aluminium and hardly formable ultra-high-strength steels (UHSS). This innovative technology joins in a single-stage process without any pilot-hole, surface pre-treatment or auxiliary joining part. The combination of an inner and outer punch realises an indirect cutting operation of the die-sided material, whereas the punch-sided material remains unharmed. The current die-sided tool set acts as a cutting die and enables a radial extrusion of the punch-sided material after being drawn though the created hole in the UHSS. The die has a fixed die depth. After ejecting the joined components, the slug has to be removed from the top of the spring-loaded anvil. The novel die concept investigated in this paper offers the possibility to push the slug continuously through the die in the joining direction. The removed slugs remain inside the die, so manual removal is unnecessary. The one-parted tool is supposed to be more robust than the multi-parted one that is currently used. This paper represents the task to evaluate the geometry of a useful shear-clinching die concept. To reduce the experimental effort, FEM should assist the development of the most promising approach. To quantify the success, conventional shear-clinching with opening die acts as a reference. The results show the high potential and the raison d'être of shear-clinching technologies as a mechanical joining technology for future multimaterial applications especially for UHSS.

Material properties and laser cutting of composites

NASA Astrophysics Data System (ADS)

Chen, Chia-Chieh; Cheng, Wing

Laser (Light Amplification by Stimulated Emission of Radiation) has been used successfully for many material cutting, drilling, metal welding and heat treating applications. However, laser cutting of polymer composites were attempted with varying degrees of success. Because composites are heterogeneous, the energy applied by laser could result in severe resin degradation before fibers were cut. In this study, cutting of glass, Kevlar, and graphite composites were evaluated based on their material properties and laser cutting parameters. A transient heat transfer analysis was used to determine the relative heat affected zones of these composites. Kevlar composites can be cut very well while graphite composites are difficult to cut. Though the cutting process is much more complicated in reality, the analysis provides a semi-quantitative perspective on the characteristics and limitations of laser cutting of different composites.

Development of thermal model to analyze thermal flux distribution in thermally enhanced machining of high chrome white cast iron

NASA Astrophysics Data System (ADS)

Ravi, A. M.; Murigendrappa, S. M.

2018-04-01

In recent times, thermally enhanced machining (TEM) slowly gearing up to cut hard metals like high chrome white cast iron (HCWCI) which were impossible in conventional procedures. Also setting up of suitable cutting parameters and positioning of the heat source against the work appears to be critical in order to enhance the machinability characteristics of the work material. In this research work, the Oxy - LPG flame was used as the heat source and HCWCI as the workpiece. ANSYS-CFD-Flow software was used to develop the transient thermal model to analyze the thermal flux distribution on the work surface during TEM of HCWCI using Cubic boron nitride (CBN) tools. Non-contact type Infrared thermo sensor was used to measure the surface temperature continuously at different positions, and is validated with the thermal model results. The result confirms thermal model is a better predictive tool for thermal flux distribution analysis in TEM process.

Rapid Active Sampling Package

NASA Technical Reports Server (NTRS)

Peters, Gregory

2010-01-01

A field-deployable, battery-powered Rapid Active Sampling Package (RASP), originally designed for sampling strong materials during lunar and planetary missions, shows strong utility for terrestrial geological use. The technology is proving to be simple and effective for sampling and processing materials of strength. Although this originally was intended for planetary and lunar applications, the RASP is very useful as a powered hand tool for geologists and the mining industry to quickly sample and process rocks in the field on Earth. The RASP allows geologists to surgically acquire samples of rock for later laboratory analysis. This tool, roughly the size of a wrench, allows the user to cut away swaths of weathering rinds, revealing pristine rock surfaces for observation and subsequent sampling with the same tool. RASPing deeper (.3.5 cm) exposes single rock strata in-situ. Where a geologist fs hammer can only expose unweathered layers of rock, the RASP can do the same, and then has the added ability to capture and process samples into powder with particle sizes less than 150 microns, making it easier for XRD/XRF (x-ray diffraction/x-ray fluorescence). The tool uses a rotating rasp bit (or two counter-rotating bits) that resides inside or above the catch container. The container has an open slot to allow the bit to extend outside the container and to allow cuttings to enter and be caught. When the slot and rasp bit are in contact with a substrate, the bit is plunged into it in a matter of seconds to reach pristine rock. A user in the field may sample a rock multiple times at multiple depths in minutes, instead of having to cut out huge, heavy rock samples for transport back to a lab for analysis. Because of the speed and accuracy of the RASP, hundreds of samples can be taken in one day. RASP-acquired samples are small and easily carried. A user can characterize more area in less time than by using conventional methods. The field-deployable RASP used a Ni/Cad rechargeable battery. Power usage was less than 1 Wh/ cm3 even when sampling strong basalts, so many samples could be taken on a single battery charge.

Analytical model for force prediction when machining metal matrix composites

NASA Astrophysics Data System (ADS)

Sikder, Snahungshu

Metal Matrix Composites (MMC) offer several thermo-mechanical advantages over standard materials and alloys which make them better candidates in different applications. Their light weight, high stiffness, and strength have attracted several industries such as automotive, aerospace, and defence for their wide range of products. However, the wide spread application of Meal Matrix Composites is still a challenge for industry. The hard and abrasive nature of the reinforcement particles is responsible for rapid tool wear and high machining costs. Fracture and debonding of the abrasive reinforcement particles are the considerable damage modes that directly influence the tool performance. It is very important to find highly effective way to machine MMCs. So, it is important to predict forces when machining Metal Matrix Composites because this will help to choose perfect tools for machining and ultimately save both money and time. This research presents an analytical force model for predicting the forces generated during machining of Metal Matrix Composites. In estimating the generated forces, several aspects of cutting mechanics were considered including: shearing force, ploughing force, and particle fracture force. Chip formation force was obtained by classical orthogonal metal cutting mechanics and the Johnson-Cook Equation. The ploughing force was formulated while the fracture force was calculated from the slip line field theory and the Griffith theory of failure. The predicted results were compared with previously measured data. The results showed very good agreement between the theoretically predicted and experimentally measured cutting forces.

Cutting force measurement of electrical jigsaw by strain gauges

NASA Astrophysics Data System (ADS)

Kazup, L.; Varadine Szarka, A.

2016-11-01

This paper describes a measuring method based on strain gauges for accurate specification of electric jigsaw's cutting force. The goal of the measurement is to provide an overall perspective about generated forces in a jigsaw's gearbox during a cutting period. The lifetime of the tool is affected by these forces primarily. This analysis is part of the research and development project aiming to develop a special linear magnetic brake for realizing automatic lifetime tests of electric jigsaws or similar handheld tools. The accurate specification of cutting force facilitates to define realistic test cycles during the automatic lifetime test. The accuracy and precision resulted by the well described cutting force characteristic and the possibility of automation provide new dimension for lifetime testing of the handheld tools with alternating movement.

Open ended tubing cutters

NASA Technical Reports Server (NTRS)

Girala, A. S. (Inventor)

1981-01-01

A self clamping cutting tool which includes a handle attached to a C-shaped housing is described. Rotatably mounted within the housing is a C-shaped tool body carrying a set of clamping rolls, two support rolls, and an edged cutting roll (64). The support rolls are disposed to one side of the axis of a pipe and the cutting roll is disposed to the other side of a pipe axis so that these rolls contact a pipe at three circumferential points. Cutter advancing apparatus advance the cutting roll toward the support rollers. The support rolls and cutting roll are rotatable independently of the C-shaped housing. A one way ratchet mechanism disposed between the C-shaped housing and the C-shaped tool body permits operation by movement in one rotational direction about the pipe axis.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bunshah, R.F.; Shabaik, A.H.

The process of Activated Reactive Evaporation is used to synthesize superhard materials like carbides, oxides, nitrides and ultrafine grain cermets. The deposits are characterized by hardness, microstructure, microprobe analysis for chemistry and lattice parameter measurements. The synthesis and characterization of TiC-Ni cermets and Al/sub 2/O/sub 3/ are given. High speed steel tool coated with TiC, TiC-Ni and TaC are tested for machining performance at different speeds and feeds. The machining evaluation and the selection of coatings is based on the rate of deterioration of the coating tool temperature, and cutting forces. Tool life tests show coated high speed steel toolsmore » having 150 to 300% improvement in tool life compared to uncoated tools. Variability in the quality of the ground edge on high speed steel inserts produce a great scatter in the machining evaluation data.« less

Lectures on Composite Materials for Aircraft Structures,

DTIC Science & Technology

1982-10-01

9 Moh), derived composites can be machined only with great difficulty, with diamond-tipped tools. 2.4 Aramid Fibres These fibres are the latest type...between fibrils. Failed specimens often give the appearance of broomsticks due to this failure mode. Machining of Kevlar composites requires careful...Compressive Strength of Kevlar 49/Epoxy Composites , Composites , vol. 6, pp. 217-225, 1975. 13. Anon., A Guide to Cutting and Machining Kevlar Aramid, Du

Hole expansion test of third generation steels

NASA Astrophysics Data System (ADS)

Agirre, Julen; Mendiguren, Joseba; Galdos, Lander; de Argandoña, Eneko Sáenz

2017-10-01

The trend towards the implementation of new materials in the chassis of the automobiles is considerably making more complex the manufacturing of the components that built it up. In this scenario materials with higher strengths and lower formabilities are daily faced by tool makers and component producers what reduces the process windows and makes the forming processes to be in the limits of the materials. One of the concerns that tool makers must face during the definition of the tools is the expansion ratios that the holes in the sheet may reach before producing a breakage due to the stretching of the material (also known as edge cracks). For the characterization of such limits, a standard test, the hole expansion test, can be applied so that the limits of the material are known. At the present study, hole expansion tests of a third generation steel, Fortiform1050 with a thickness of 1.2 millimeters have been carried out and compared them to a mild steel, DX54D with a thickness of 0.6 millimeters. A comparison for each material in terms of technology used to punch the hole, mechanical punching vs laser cutting has also been conducted. In addition, the measurement technique (online measurement vs offline measurement) followed in the Hole Expansion Ratio (HER) identification has also been analyzed. Finally, differences between both materials and techniques are presented.

Acoustic emission analysis for the detection of appropriate cutting operations in honing processes

NASA Astrophysics Data System (ADS)

Buj-Corral, Irene; Álvarez-Flórez, Jesús; Domínguez-Fernández, Alejandro

2018-01-01

In the present paper, acoustic emission was studied in honing experiments obtained with different abrasive densities, 15, 30, 45 and 60. In addition, 2D and 3D roughness, material removal rate and tool wear were determined. In order to treat the sound signal emitted during the machining process, two methods of analysis were compared: Fast Fourier Transform (FFT) and Hilbert Huang Transform (HHT). When density 15 is used, the number of cutting grains is insufficient to provide correct cutting, while clogging appears with densities 45 and 60. The results were confirmed by means of treatment of the sound signal. In addition, a new parameter S was defined as the relationship between energy in low and high frequencies contained within the emitted sound. The selected density of 30 corresponds to S values between 0.1 and 1. Correct cutting operations in honing processes are dependent on the density of the abrasive employed. The density value to be used can be selected by means of measurement and analysis of acoustic emissions during the honing operation. Thus, honing processes can be monitored without needing to stop the process.

Successful fabrication of a convex platform PMMA cell-counting slide using a high-precision perpendicular dual-spindle CNC machine tool

NASA Astrophysics Data System (ADS)

Chen, Shun-Tong; Chang, Chih-Hsien

2013-12-01

This study presents a novel approach to the fabrication of a biomedical-mold for producing convex platform PMMA (poly-methyl-meth-acrylate) slides for counting cells. These slides allow for the microscopic examination of urine sediment cells. Manufacturing of such slides incorporates three important procedures: (1) the development of a tabletop high-precision dual-spindle CNC (computerized numerical control) machine tool; (2) the formation of a boron-doped polycrystalline composite diamond (BD-PCD) wheel-tool on the machine tool developed in procedure (1); and (3) the cutting of a multi-groove-biomedical-mold array using the formed diamond wheel-tool in situ on the developed machine. The machine incorporates a hybrid working platform providing wheel-tool thinning using spark erosion to cut, polish, and deburr microgrooves on NAK80 steel directly. With consideration given for the electrical conductive properties of BD-PCD, the diamond wheel-tool is thinned to a thickness of 5 µm by rotary wire electrical discharge machining. The thinned wheel-tool can grind microgrooves 10 µm wide. An embedded design, which inserts a close fitting precision core into the biomedical-mold to create step-difference (concave inward) of 50 µm in height between the core and the mold, is also proposed and realized. The perpendicular dual-spindles and precision rotary stage are features that allow for biomedical-mold machining without the necessity of uploading and repositioning materials until all tasks are completed. A PMMA biomedical-slide with a plurality of juxtaposed counting chambers is formed and its usefulness verified.

Modeling of tool path for the CNC sheet cutting machines

NASA Astrophysics Data System (ADS)

Petunin, Aleksandr A.

2015-11-01

In the paper the problem of tool path optimization for CNC (Computer Numerical Control) cutting machines is considered. The classification of the cutting techniques is offered. We also propose a new classification of toll path problems. The tasks of cost minimization and time minimization for standard cutting technique (Continuous Cutting Problem, CCP) and for one of non-standard cutting techniques (Segment Continuous Cutting Problem, SCCP) are formalized. We show that the optimization tasks can be interpreted as discrete optimization problem (generalized travel salesman problem with additional constraints, GTSP). Formalization of some constraints for these tasks is described. For the solution GTSP we offer to use mathematical model of Prof. Chentsov based on concept of a megalopolis and dynamic programming.

Detection of Cutting Tool Wear using Statistical Analysis and Regression Model

NASA Astrophysics Data System (ADS)

Ghani, Jaharah A.; Rizal, Muhammad; Nuawi, Mohd Zaki; Haron, Che Hassan Che; Ramli, Rizauddin

2010-10-01

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals. A statistical-based method called Integrated Kurtosis-based Algorithm for Z-Filter technique, called I-kaz was used for developing a regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out using a CNC turning machine Colchester Master Tornado T4 in dry cutting condition. A Kistler 9255B dynamometer was used to measure the cutting force signals, which were transmitted, analyzed, and displayed in the DasyLab software. Various force signals from machining operation were analyzed, and each has its own I-kaz 3D coefficient. This coefficient was examined and its relationship with flank wear lands (VB) was determined. A regression model was developed due to this relationship, and results of the regression model shows that the I-kaz 3D coefficient value decreases as tool wear increases. The result then is used for real time tool wear monitoring.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

NASA Technical Reports Server (NTRS)

Fragomeni, James M.

1996-01-01

In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

Simulating Extraterrestrial Ices in the Laboratory

NASA Astrophysics Data System (ADS)

Berisford, D. F.; Carey, E. M.; Hand, K. P.; Choukroun, M.

2017-12-01

Several ongoing experiments at JPL attempt to simulate the ice environment for various regimes associated with icy moons. The Europa Penitent Ice Experiment (EPIX) simulates the surface environment of an icy moon, to investigate the physics of ice surface morphology growth. This experiment features half-meter-scale cryogenic ice samples, cryogenic radiative sink environment, vacuum conditions, and diurnal cycling solar simulation. The experiment also includes several smaller fixed-geometry vacuum chambers for ice simulation at Earth-like and intermediate temperature and vacuum conditions for development of surface morphology growth scaling relations. Additionally, an ice cutting facility built on a similar platform provides qualitative data on the mechanical behavior of cryogenic ice with impurities under vacuum, and allows testing of ice cutting/sampling tools relevant for landing spacecraft. A larger cutting facility is under construction at JPL, which will provide more quantitative data and allow full-scale sampling tool tests. Another facility, the JPL Ice Physics Laboratory, features icy analog simulant preparation abilities that range icy solar system objects such as Mars, Ceres and the icy satellites of Saturn and Jupiter. In addition, the Ice Physics Lab has unique facilities for Icy Analog Tidal Simulation and Rheological Studies of Cryogenic Icy Slurries, as well as equipment to perform thermal and mechanical properties testing on icy analog materials and their response to sinusoidal tidal stresses.

The grindability of glass fibre reinforced polymer composite

NASA Astrophysics Data System (ADS)

Chockalingam, P.

The use of glass fibre-reinforced polymer (GFRP) composite materials is extensive due to their favourable mechanical properties and near net shape production. However, almost all composite structures require post-processing operations such as grinding to meet surface finish requirements during assembly. Unlike that of conventional metal, grinding of GFRP composite needs special tools and parameters due to the abrasive nature of fibres and the delamination of the workpiece. Therefore, proper selection of the tools and parameters is important. This research aims to investigate the effects of wheel speed, feed, depth of cut, grinding wheel and coolant on the grindability of chopped strand mat (CSM) GFRP. Grinding was carried out in a precision CNC (Master-10HVA) high-speed machining centre under three conditions, namely dry, and wet conditions with synthetic coolant and emulsion coolant, using alumina wheel (OA46QV) and CBN wheel (B46QV). The grinding experiments were conducted per the central composite design of design of experiments. The grindability aspects investigated were surface area roughness (Sa) and cutting force ratio (µ). The responses were analyzed by developing fuzzy logic models. The surface area roughness and cutting force ratio values predicted by the fuzzy logic models are mostly in good agreement with experimental data, and hence conclusion was made that these models were reliable.

Study on Crystallographic Orientation Effect on Surface Generation of Aluminum in Nano-cutting

NASA Astrophysics Data System (ADS)

Xu, Feifei; Fang, Fengzhou; Zhu, Yuanqing; Zhang, Xiaodong

2017-04-01

The material characteristics such as size effect are one of the most important factors that could not be neglected in cutting the material at nanoscale. The effects of anisotropic nature of single crystal materials in nano-cutting are investigated employing the molecular dynamics simulation. Results show that the size effect of the plastic deformation is based on different plastic carriers, such as the twin, stacking faults, and dislocations. The minimum uncut chip thickness is dependent on cutting direction, where even a negative value is obtained when the cutting direction is {110}<001>. It also determines the material deformation and removal mechanism (e.g., shearing, extruding, and rubbing mechanism) with a decrease in uncut chip thickness. When material is deformed by shearing, the primary shearing zone expands from the stagnation point or the tip of stagnation zone. When a material is deformed by extruding and rubbing, the primary deformation zone almost parallels to the cutting direction and expands from the bottom of the cutting edge merging with the tertiary deformation zone. The generated surface quality relates to the crystallographic orientation and the minimum uncut chip thickness. The cutting directions of {110}<001>, {110}<1-10>, and {111}<1-10>, whose minimum uncut chip thickness is relatively small, have better surface qualities compared to the other cutting direction.

Study on Crystallographic Orientation Effect on Surface Generation of Aluminum in Nano-cutting.

PubMed

Xu, Feifei; Fang, Fengzhou; Zhu, Yuanqing; Zhang, Xiaodong

2017-12-01

The material characteristics such as size effect are one of the most important factors that could not be neglected in cutting the material at nanoscale. The effects of anisotropic nature of single crystal materials in nano-cutting are investigated employing the molecular dynamics simulation. Results show that the size effect of the plastic deformation is based on different plastic carriers, such as the twin, stacking faults, and dislocations. The minimum uncut chip thickness is dependent on cutting direction, where even a negative value is obtained when the cutting direction is {110}<001>. It also determines the material deformation and removal mechanism (e.g., shearing, extruding, and rubbing mechanism) with a decrease in uncut chip thickness. When material is deformed by shearing, the primary shearing zone expands from the stagnation point or the tip of stagnation zone. When a material is deformed by extruding and rubbing, the primary deformation zone almost parallels to the cutting direction and expands from the bottom of the cutting edge merging with the tertiary deformation zone. The generated surface quality relates to the crystallographic orientation and the minimum uncut chip thickness. The cutting directions of {110}<001>, {110}<1-10>, and {111}<1-10>, whose minimum uncut chip thickness is relatively small, have better surface qualities compared to the other cutting direction.

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718.

PubMed

Wang, Bing; Liu, Zhanqiang; Hou, Xin; Zhao, Jinfu

2018-03-21

The paper aims to investigate the influences of material constitutive and fracture parameters in addition to cutting speed on chip formation during high-speed cutting of Inconel 718. Finite element analyses for chip formation are conducted with Johnson-Cook constitutive and fracture models. Meanwhile, experiments of high-speed orthogonal cutting are performed to verify the simulation results with cutting speeds ranging from 50 m/min to 7000 m/min. The research indicates that the chip morphology transforms from serrated to fragmented at the cutting speed of 7000 m/min due to embrittlement of the workpiece material under ultra-high cutting speeds. The parameter of shear localization sensitivity is put forward to describe the influences of material mechanical properties on serrated chip formation. The results demonstrate that the effects of initial yield stress and thermal softening coefficient on chip shear localization are much more remarkable than the other constitutive parameters. For the material fracture parameters, the effects of initial fracture strain and exponential factor of stress state on chip shear localization are more much prominent. This paper provides guidance for controlling chip formation through the adjustment of material mechanical properties and the selection of appropriate cutting parameters.

Influences of Cutting Speed and Material Mechanical Properties on Chip Deformation and Fracture during High-Speed Cutting of Inconel 718

PubMed Central

Hou, Xin; Zhao, Jinfu

2018-01-01

The paper aims to investigate the influences of material constitutive and fracture parameters in addition to cutting speed on chip formation during high-speed cutting of Inconel 718. Finite element analyses for chip formation are conducted with Johnson–Cook constitutive and fracture models. Meanwhile, experiments of high-speed orthogonal cutting are performed to verify the simulation results with cutting speeds ranging from 50 m/min to 7000 m/min. The research indicates that the chip morphology transforms from serrated to fragmented at the cutting speed of 7000 m/min due to embrittlement of the workpiece material under ultra-high cutting speeds. The parameter of shear localization sensitivity is put forward to describe the influences of material mechanical properties on serrated chip formation. The results demonstrate that the effects of initial yield stress and thermal softening coefficient on chip shear localization are much more remarkable than the other constitutive parameters. For the material fracture parameters, the effects of initial fracture strain and exponential factor of stress state on chip shear localization are more much prominent. This paper provides guidance for controlling chip formation through the adjustment of material mechanical properties and the selection of appropriate cutting parameters. PMID:29561770

Diamond Coatings

NASA Technical Reports Server (NTRS)

1990-01-01

Advances in materials technology have demonstrated that it is possible to get the advantages of diamond in a number of applications without the cost penalty, by coating and chemically bonding an inexpensive substrate with a thin film of diamond-like carbon (DLC). Diamond films offer tremendous technical and economic potential in such advances as chemically inert protective coatings; machine tools and parts capable of resisting wear 10 times longer; ball bearings and metal cutting tools; a broad variety of optical instruments and systems; and consumer products. Among the American companies engaged in DLC commercialization is Diamonex, Inc., a diamond coating spinoff of Air Products and Chemicals, Inc. Along with its own proprietary technology for both polycrystalline diamond and DLC coatings, Diamonex is using, under an exclusive license, NASA technology for depositing DLC on a substrate. Diamonex is developing, and offering commercially, under the trade name Diamond Aegis, a line of polycrystalline diamond-coated products that can be custom tailored for optical, electronic and engineering applications. Diamonex's initial focus is on optical products and the first commercial product is expected in late 1990. Other target applications include electronic heat sink substrates, x-ray lithography masks, metal cutting tools and bearings.

Joining dissimilar materials using Friction Stir scribe technique

DOE Office of Scientific and Technical Information (OSTI.GOV)

Upadhyay, Piyush; Hovanski, Yuri; Jana, Saumyadeep

2016-10-03

The ability to effectively join materials with vastly different melting points like Aluminum-Steel, Polymer composites - metals has been one of the road blocks in realizing multi-material components for light weighting efforts. Friction stir scribe (FSS) technique is a promising method that produces continuous overlap joint between materials with vastly different melting regimes and high temperature flow characteristics. FSS uses an offset cutting tool at the tip of the FSW pin to create an insitu mechanical interlock between material interfaces. With investments from Vehicle Technology office, US DOE and several automotive manufacturers and suppliers PNNL is developing the FSS processmore » and has demonstrated viability of joining several material combinations. Details of welding trails, unique challenges and mitigation strategies in different material combinations will be discussed. Joint characterization including mechanical tests and joint performances will also be presented.« less

Grinding, Machining Morphological Studies on C/SiC Composites

NASA Astrophysics Data System (ADS)

Xiao, Chun-fang; Han, Bing

2018-05-01

C/SiC composite is a typical material difficult to machine. It is hard and brittle. In machining, the cutting force is large, the material removal rate is low, the edge is prone to collapse, and the tool wear is serious. In this paper, the grinding of C/Si composites material along the direction of fiber distribution is studied respectively. The surface microstructure and mechanical properties of C/SiC composites processed by ultrasonic machining were evaluated. The change of surface quality with the change of processing parameters has also been studied. By comparing the performances of conventional grinding and ultrasonic grinding, the surface roughness and functional characteristics of the material can be improved by optimizing the processing parameters.

Modeling and analysis of the chip formation and transient cutting force during elliptical vibration cutting process

NASA Astrophysics Data System (ADS)

Lin, Jieqiong; Guan, Liang; Lu, Mingming; Han, Jinguo; Kan, Yudi

2017-12-01

In traditional diamond cutting, the cutting force is usually large and it will affect tool life and machining quality. Elliptical vibration cutting (EVC) as one of the ultra-precision machining technologies has a lot of advantages, such as reduces cutting force, extend tool life and so on. It's difficult to predict the transient cutting force of EVC due to its unique elliptical motion trajectory. Study on chip formation will helpfully to predict cutting force. The geometric feature of chip has important effects on cutting force, however, few scholars have studied the chip formation. In order to investigate the time-varying cutting force of EVC, the geometric feature model of chip is established based on analysis of chip formation, and the effects of cutting parameters on the geometric feature of chip are analyzed. To predict transient force quickly and effectively, the geometric feature of chip is introduced into the cutting force model. The calculated results show that the error between the predicted cutting force in this paper and that in the literature is less than 2%, which proves its feasibility.

Ductile cutting of silicon microstructures with surface inclination measurement and compensation by using a force sensor integrated single point diamond tool

NASA Astrophysics Data System (ADS)

Chen, Yuan-Liu; Cai, Yindi; Shimizu, Yuki; Ito, So; Gao, Wei; Ju, Bing-Feng

2016-02-01

This paper presents a measurement and compensation method of surface inclination for ductile cutting of silicon microstructures by using a diamond tool with a force sensor based on a four-axis ultra-precision lathe. The X- and Y-directional inclinations of a single crystal silicon workpiece with respect to the X- and Y-motion axes of the lathe slides were measured respectively by employing the diamond tool as a touch-trigger probe, in which the tool-workpiece contact is sensitively detected by monitoring the force sensor output. Based on the measurement results, fabrication of silicon microstructures can be thus carried out directly along the tilted silicon workpiece by compensating the cutting motion axis to be parallel to the silicon surface without time-consuming pre-adjustment of the surface inclination or turning of a flat surface. A diamond tool with a negative rake angle was used in the experiment for superior ductile cutting performance. The measurement precision by using the diamond tool as a touch-trigger probe was investigated. Experiments of surface inclination measurement and ultra-precision ductile cutting of a micro-pillar array and a micro-pyramid array with inclination compensation were carried out respectively to demonstrate the feasibility of the proposed method.

Engineering the shape and structure of materials by fractal cut.

PubMed

Cho, Yigil; Shin, Joong-Ho; Costa, Avelino; Kim, Tae Ann; Kunin, Valentin; Li, Ju; Lee, Su Yeon; Yang, Shu; Han, Heung Nam; Choi, In-Suk; Srolovitz, David J

2014-12-09

In this paper we discuss the transformation of a sheet of material into a wide range of desired shapes and patterns by introducing a set of simple cuts in a multilevel hierarchy with different motifs. Each choice of hierarchical cut motif and cut level allows the material to expand into a unique structure with a unique set of properties. We can reverse-engineer the desired expanded geometries to find the requisite cut pattern to produce it without changing the physical properties of the initial material. The concept was experimentally realized and applied to create an electrode that expands to >800% the original area with only very minor stretching of the underlying material. The generality of our approach greatly expands the design space for materials so that they can be tuned for diverse applications.

Optimization of cutting parameters in CNC turning of stainless steel 304 with TiAlN nano coated carbide cutting tool

NASA Astrophysics Data System (ADS)

Durga Prasada Rao, V.; Harsha, N.; Raghu Ram, N. S.; Navya Geethika, V.

2018-02-01

In this work, turning was performed to optimize the surface finish or roughness (Ra) of stainless steel 304 with uncoated and coated carbide tools under dry conditions. The carbide tools were coated with Titanium Aluminium Nitride (TiAlN) nano coating using Physical Vapour Deposition (PVD) method. The machining parameters, viz., cutting speed, depth of cut and feed rate which show major impact on Ra are considered during turning. The experiments are designed as per Taguchi orthogonal array and machining process is done accordingly. Then second-order regression equations have been developed on the basis of experimental results for Ra in terms of machining parameters used. Regarding the effect of machining parameters, an upward trend is observed in Ra with respect to feed rate, and as cutting speed increases the Ra value increased slightly due to chatter and vibrations. The adequacy of response variable (Ra) is tested by conducting additional experiments. The predicted Ra values are found to be a close match of their corresponding experimental values of uncoated and coated tools. The corresponding average % errors are found to be within the acceptable limits. Then the surface roughness equations of uncoated and coated tools are set as the objectives of optimization problem and are solved by using Differential Evolution (DE) algorithm. Also the tool lives of uncoated and coated tools are predicted by using Taylor’s tool life equation.

Tube cutter tool and method of use for coupon removal

DOEpatents

Nachbar, H.D.; Etten, M.P. Jr.; Kurowski, P.A.

1997-05-06

A tube cutter tool is insertable into a tube for cutting a coupon from a damaged site on the exterior of the tube. Prior to using the tool, the damaged site is first located from the interior of the tube using a multi-coil pancake eddy current test probe. The damaged site is then marked. A fiber optic probe is used to monitor the subsequent cutting procedure which is performed using a hole saw mounted on the tube cutter tool. Prior to completion of the cutting procedure, a drill in the center of the hole saw is drilled into the coupon to hold it in place. 4 figs.

Tube cutter tool and method of use for coupon removal

DOEpatents

Nachbar, Henry D.; Etten, Jr., Marvin P.; Kurowski, Paul A.

1997-01-01

A tube cutter tool is insertable into a tube for cutting a coupon from a damaged site on the exterior of the tube. Prior to using the tool, the damaged site is first located from the interior of the tube using a multi-coil pancake eddy current test probe. The damaged site is then marked. A fiber optic probe is used to monitor the subsequent cutting procedure which is performed using a hole saw mounted on the tube cutter tool. Prior to completion of the cutting procedure, a drill in the center of the hole saw is drilled into the coupon to hold it in place.

Tribology in secondary wood machining

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ko, P.L.; Hawthorne, H.M.; Andiappan, J.

Secondary wood manufacturing covers a wide range of products from furniture, cabinets, doors and windows, to musical instruments. Many of these are now mass produced in sophisticated, high speed numerical controlled machines. The performance and the reliability of the tools are key to an efficient and economical manufacturing process as well as to the quality of the finished products. A program concerned with three aspects of tribology of wood machining, namely, tool wear, tool-wood friction characteristics and wood surface quality characterization, was set up in the Integrated Manufacturing Technologies Institute (IMTI) of the National Research Council of Canada. The studiesmore » include friction and wear mechanism identification and modeling, wear performance of surface-engineered tool materials, friction-induced vibration and cutting efficiency, and the influence of wear and friction on finished products. This research program underlines the importance of tribology in secondary wood manufacturing and at the same time adds new challenges to tribology research since wood is a complex, heterogeneous, material and its behavior during machining is highly sensitive to the surrounding environments and to the moisture content in the work piece.« less

Green Turning of FCD 700 Ductile Cast Iron Using Coated Carbide Tool

NASA Astrophysics Data System (ADS)

Rodzi, Mohd Nor Azmi Mohd; Ghani, Jaharah A.; Eghawail, A. M.; Othman, Kamal; Rahman, Mohd. Nizam Ab.; Haron, Che Hassan Che

2010-10-01

This paper presents the performance of carbide coated cutting insert in turning FCD700 ductile cast iron in various dry machining conditions (without air, using air and chilled air). The turning parameters studied were, cutting speed of 120 m/min., feed rate of 0.15 mm/rev-0.4 mm/rev, and depth of cut of 0.6 mm-1.0 mm. The results show that the tool life was significantly controlled by the type of air coolant used, whereas the cutting force and surface roughness were not influenced by these coolants. Chilled air was found to be significantly improved the tool life by about 30% and 40% respectively when compared with normal air and without air conditions. The wear mechanism was predominantly controlled by the flank and crater wears on the flank and rake faces respectively. Due to the low cutting speed used in the experiment, both flank and crater wears were uniformly formed along the cutting edge and no catastrophic failure was observed under the scanning electron microscope (SEM).

[ABC supplies classification: a managment tool of costs in nursing].

PubMed

Lourenço, Karina Gomes; Castilho, Valéria

2006-01-01

The implementation of costs management systems has been extremely helpful to healthcare area owing to their efficacy in cutting expenditures as well as improving service quality. The ABC classification is an applied strategy to stocktaking and control. The research, which consists of an exploratory/descriptive quantitative analysis, has been carried out in order to identify, in a year time period, the demand for supplies at Universidade de Sao Paulo's Hospital. Of 1938 classified materials, 67 itens had been classified that they correspond to the materials with bigger costs for the hospital. 31.3% of these A-Class supplies catalogued items are the nursing materials, more used for the nursing team.

Metafusion: A breakthrough in metallurgy

NASA Technical Reports Server (NTRS)

Joseph, Adrian A.

1994-01-01

The Metafuse Process is a patented development in the field of thin film coatings utilizing cold fusion which results in a true inter-dispersion of dissimilar materials along a gradual transition gradient through a boundary of several hundred atomic layers. The process is performed at ambient temperatures and pressures requiring relatively little energy and creating little or no heat. The process permits a remarkable range of material combinations and joining of materials which are normally incompatible. Initial applications include titanium carbide into and onto the copper resistance welding electrodes and tungsten carbide onto the cutting edges of tool steel blades. The process is achieved through application of an RF signal of low power and is based on the theory of vacancy fusion.

Quantitative assessment of the enamel machinability in tooth preparation with dental diamond burs.

PubMed

Song, Xiao-Fei; Jin, Chen-Xin; Yin, Ling

2015-01-01

Enamel cutting using dental handpieces is a critical process in tooth preparation for dental restorations and treatment but the machinability of enamel is poorly understood. This paper reports on the first quantitative assessment of the enamel machinability using computer-assisted numerical control, high-speed data acquisition, and force sensing systems. The enamel machinability in terms of cutting forces, force ratio, cutting torque, cutting speed and specific cutting energy were characterized in relation to enamel surface orientation, specific material removal rate and diamond bur grit size. The results show that enamel surface orientation, specific material removal rate and diamond bur grit size critically affected the enamel cutting capability. Cutting buccal/lingual surfaces resulted in significantly higher tangential and normal forces, torques and specific energy (p<0.05) but lower cutting speeds than occlusal surfaces (p<0.05). Increasing material removal rate for high cutting efficiencies using coarse burs yielded remarkable rises in cutting forces and torque (p<0.05) but significant reductions in cutting speed and specific cutting energy (p<0.05). In particular, great variations in cutting forces, torques and specific energy were observed at the specific material removal rate of 3mm(3)/min/mm using coarse burs, indicating the cutting limit. This work provides fundamental data and the scientific understanding of the enamel machinability for clinical dental practice. Copyright © 2014 Elsevier Ltd. All rights reserved.

Performance analysis of cutting graphite-epoxy composite using a 90,000psi abrasive waterjet

NASA Astrophysics Data System (ADS)

Choppali, Aiswarya

Graphite-epoxy composites are being widely used in many aerospace and structural applications because of their properties: which include lighter weight, higher strength to weight ratio and a greater flexibility in design. However, the inherent anisotropy of these composites makes it difficult to machine them using conventional methods. To overcome the major issues that develop with conventional machining such as fiber pull out, delamination, heat generation and high tooling costs, an effort is herein made to study abrasive waterjet machining of composites. An abrasive waterjet is used to cut 1" thick graphite epoxy composites based on baseline data obtained from the cutting of ¼" thick material. The objective of this project is to study the surface roughness of the cut surface with a focus on demonstrating the benefits of using higher pressures for cutting composites. The effects of major cutting parameters: jet pressure, traverse speed, abrasive feed rate and cutting head size are studied at different levels. Statistical analysis of the experimental data provides an understanding of the effect of the process parameters on surface roughness. Additionally, the effect of these parameters on the taper angle of the cut is studied. The data is analyzed to obtain a set of process parameters that optimize the cutting of 1" thick graphite-epoxy composite. The statistical analysis is used to validate the experimental data. Costs involved in the cutting process are investigated in term of abrasive consumed to better understand and illustrate the practical benefits of using higher pressures. It is demonstrated that, as pressure increased, ultra-high pressure waterjets produced a better surface quality at a faster traverse rate with lower costs.

Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components

NASA Technical Reports Server (NTRS)

Bednarcyk, Brett A.

2005-01-01

This document is the final report for the project entitled, "Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components," funded under the NRA entitled "Cross-Enterprise Technology Development Program" issued by the NASA Office of Space Science in 2000. The project was funded in 2001, and spanned a four year period from March, 2001 to February, 2005. Through enhancements to and synthesis of unique, state of the art structural mechanics and micromechanics analysis software, a new multi-scale tool has been developed that enables design, analysis, and sizing of advance lightweight composite and smart materials and structures from the full vehicle, to the stiffened structure, to the micro (fiber and matrix) scales. The new software tool has broad, cross-cutting value to current and future NASA missions that will rely on advanced composite and smart materials and structures.

Smart tool holder

DOEpatents

Day, Robert Dean; Foreman, Larry R.; Hatch, Douglas J.; Meadows, Mark S.

1998-01-01

There is provided an apparatus for machining surfaces to accuracies within the nanometer range by use of electrical current flow through the contact of the cutting tool with the workpiece as a feedback signal to control depth of cut.

On-line Monitoring for Cutting Tool Wear Condition Based on the Parameters

NASA Astrophysics Data System (ADS)

Han, Fenghua; Xie, Feng

2017-07-01

In the process of cutting tools, it is very important to monitor the working state of the tools. On the basis of acceleration signal acquisition under the constant speed, time domain and frequency domain analysis of relevant indicators monitor the online of tool wear condition. The analysis results show that the method can effectively judge the tool wear condition in the process of machining. It has certain application value.

On-line Tool Wear Detection on DCMT070204 Carbide Tool Tip Based on Noise Cutting Audio Signal using Artificial Neural Network

NASA Astrophysics Data System (ADS)

Prasetyo, T.; Amar, S.; Arendra, A.; Zam Zami, M. K.

2018-01-01

This study develops an on-line detection system to predict the wear of DCMT070204 tool tip during the cutting process of the workpiece. The machine used in this research is CNC ProTurn 9000 to cut ST42 steel cylinder. The audio signal has been captured using the microphone placed in the tool post and recorded in Matlab. The signal is recorded at the sampling rate of 44.1 kHz, and the sampling size of 1024. The recorded signal is 110 data derived from the audio signal while cutting using a normal chisel and a worn chisel. And then perform signal feature extraction in the frequency domain using Fast Fourier Transform. Feature selection is done based on correlation analysis. And tool wear classification was performed using artificial neural networks with 33 input features selected. This artificial neural network is trained with back propagation method. Classification performance testing yields an accuracy of 74%.

Material cutting, shaping, and forming: A compilation

NASA Technical Reports Server (NTRS)

1974-01-01

Information is presented concerning cutting, shaping, and forming of materials, and the equipment and techniques required for utilizing these materials. The use of molds, electrical fields, and mechanical devices are related to forming materials. Material cutting methods by devices including borers and slicers are presented along with chemical techniques. Shaping and fabrication techniques are described for tubing, honeycomb panels, and ceramic structures. The characteristics of the materials are described. Patent information is included.

A novel toolpath force prediction algorithm using CAM volumetric data for optimizing robotic arthroplasty.

PubMed

Kianmajd, Babak; Carter, David; Soshi, Masakazu

2016-10-01

Robotic total hip arthroplasty is a procedure in which milling operations are performed on the femur to remove material for the insertion of a prosthetic implant. The robot performs the milling operation by following a sequential list of tool motions, also known as a toolpath, generated by a computer-aided manufacturing (CAM) software. The purpose of this paper is to explain a new toolpath force prediction algorithm that predicts cutting forces, which results in improving the quality and safety of surgical systems. With a custom macro developed in the CAM system's native application programming interface, cutting contact patch volume was extracted from CAM simulations. A time domain cutting force model was then developed through the use of a cutting force prediction algorithm. The second portion validated the algorithm by machining a hip canal in simulated bone using a CNC machine. Average cutting forces were measured during machining using a dynamometer and compared to the values predicted from CAM simulation data using the proposed method. The results showed the predicted forces matched the measured forces in both magnitude and overall pattern shape. However, due to inconsistent motion control, the time duration of the forces was slightly distorted. Nevertheless, the algorithm effectively predicted the forces throughout an entire hip canal procedure. This method provides a fast and easy technique for predicting cutting forces during orthopedic milling by utilizing data within a CAM software.

Smart tool holder

DOEpatents

Day, R.D.; Foreman, L.R.; Hatch, D.J.; Meadows, M.S.

1998-09-08

There is provided an apparatus for machining surfaces to accuracies within the nanometer range by use of electrical current flow through the contact of the cutting tool with the workpiece as a feedback signal to control depth of cut. 3 figs.

Comparison of cutting efficiencies between electric and air-turbine dental handpieces.

PubMed

Choi, Charlson; Driscoll, Carl F; Romberg, Elaine

2010-02-01

Dentistry is gravitating toward the increased use of electric handpieces. The dental professional should have sufficient evidence to validate the switch from an air-turbine handpiece to an electric handpiece. However, there is little research quantifying the cutting efficiency of electric and air-turbine handpieces. Studies that do quantify cutting efficiency typically do so with only a single material. The purpose of this study was to compare the cutting efficiency of an electric handpiece and an air-turbine handpiece, using various materials commonly used in dentistry. Seven materials: Macor (machinable glass ceramic), silver amalgam, aluminum oxide, zirconium oxide, high noble metal alloy, noble metal alloy, and base metal alloy, were each cut with a bur 220 times; 110 times with an electric handpiece, and 110 times with an air-turbine handpiece. The weight difference of the material was calculated by subtracting the weight of the material after a cut from the weight of the material before the cut. The cutting efficiency was calculated by dividing the weight difference by the duration of the cut (g/s). Data were analyzed by a 2-way analysis of variance followed by Tukey's Honestly Significant Difference (HSD) test (alpha=.05). The electric handpiece cut more efficiently than the air-turbine handpiece (F=3098.9, P<.001). In particular, the high noble metal alloy, silver amalgam, and Macor were cut more efficiently with the electric handpiece (0.0383 +/-0.0002 g/s, 0.0260 +/-0.0002 g/s, and 0.0122 +/-0.0002 g/s, respectively) than with the air-turbine handpiece (0.0125 +/-0.0002 g/s, 0.0142 +/-0.0002 g/s, and 0.008 +/-0.0002 g/s, respectively). The electric handpiece is more efficient at cutting various materials used in dentistry, especially machinable glass ceramic, silver amalgam, and high noble alloy, than the air-turbine handpiece.

Application of carbide cutting tools with nano-structured multilayer composite coatings for turning austenitic steels, type 16Cr-10NI

NASA Astrophysics Data System (ADS)

Vereschaka, Alexey; Migranov, Mars; Oganyan, Gaik; Sotova, Catherine S.; Batako, Andre

2018-03-01

This paper addresses the challenges of increasing the efficiency of the machining of austenitic stainless steels AISI 321 and S31600 by application of cutting tools with multilayer composite nano-structured coatings. The main mechanical properties and internal structures of the coatings under study (hardness, adhesion strength in the "coating-substrate" system) were investigated, and their chemical compositions were analyzed. The conducted research of tool life and nature of wear of carbide tools with the investigated coatings during turning of the above mentioned steels showed that the application of those coatings increases the tool life by up to 2.5 times. In addition, the use of a cutting tool with coatings allows machining at higher cutting speeds. It was also found that the use of a tool with multilayer composite nano-structured coating (Zr,Nb)N-(Zr,Al,Nb)N ensures better results compared with not only monolithic coating TiN, but also with nano-structured coatings Ti-TiN-(Ti,Al)N and (Zr,Nb)N-(Cr,Zr,Nb,Al)N. The mechanism of failure of the coatings under study was also investigated.

Experimental Investigation of Minimum Quantity Lubrication in Meso-scale Milling with Varying Tool Diameter

NASA Astrophysics Data System (ADS)

Yusof, M. Q. M.; Harun, H. N. S. B.; Bahar, R.

2018-01-01

Minimum quantity lubrication (MQL) is a method that uses a very small amount of liquid to reduce friction between cutting tool and work piece during machining. The implementation of MQL machining has become a viable alternative to flood cooling machining and dry machining. The overall performance has been evaluated during meso-scale milling of mild steel using different diameter milling cutters. Experiments have been conducted under two different lubrication condition: dry and MQL with variable cutting parameters. The tool wear and its surface roughness, machined surfaces microstructure and surface roughness were observed for both conditions. It was found from the results that MQL produced better results compared to dry machining. The 0.5 mm tool has been selected as the most optimum tool diameter to be used with the lowest surface roughness as well as the least flank wear generation. For the workpiece, it was observed that the cutting temperature possesses crucial effect on the microstructure and the surface roughness of the machined surface and bigger diameter tool actually resulted in higher surface roughness. The poor conductivity of the cutting tool may be one of reasons behind.

Rotary fast tool servo system and methods

DOEpatents

Montesanti, Richard C.; Trumper, David L.

2007-10-02

A high bandwidth rotary fast tool servo provides tool motion in a direction nominally parallel to the surface-normal of a workpiece at the point of contact between the cutting tool and workpiece. Three or more flexure blades having all ends fixed are used to form an axis of rotation for a swing arm that carries a cutting tool at a set radius from the axis of rotation. An actuator rotates a swing arm assembly such that a cutting tool is moved in and away from the lathe-mounted, rotating workpiece in a rapid and controlled manner in order to machine the workpiece. A pair of position sensors provides rotation and position information for a swing arm to a control system. A control system commands and coordinates motion of the fast tool servo with the motion of a spindle, rotating table, cross-feed slide, and in-feed slide of a precision lathe.

Rotary fast tool servo system and methods

DOEpatents

Montesanti, Richard C [Cambridge, MA; Trumper, David L [Plaistow, NH; Kirtley, Jr., James L.

2009-08-18

A high bandwidth rotary fast tool servo provides tool motion in a direction nominally parallel to the surface-normal of a workpiece at the point of contact between the cutting tool and workpiece. Three or more flexure blades having all ends fixed are used to form an axis of rotation for a swing arm that carries a cutting tool at a set radius from the axis of rotation. An actuator rotates a swing arm assembly such that a cutting tool is moved in and away from the lathe-mounted, rotating workpiece in a rapid and controlled manner in order to machine the workpiece. One or more position sensors provides rotation and position information for a swing arm to a control system. A control system commands and coordinates motion of the fast tool servo with the motion of a spindle, rotating table, cross-feed slide, and in-feed slide of a precision lathe.

An experimental study of cutting performances in machining of nimonic super alloy GH2312

NASA Astrophysics Data System (ADS)

Du, Jinfu; Wang, Xi; Xu, Min; Mao, Jin; Zhao, Xinglong

2018-05-01

Nimonic super alloy are extensively used in the aerospace industry because of its unique properties. As they are quite costly and difficult to machine, the machining tool is easy to get worn. To solve the problem, an experiment was carried out on a numerical control slitting automatic lathe to analysis the tool wearing conditions and parts' surface quality of nimonic super alloy GH2132 under different cutters. The selection of suitable cutter, reasonable cutting data and cutting speed is obtained and some conclusions are made. The excellent coating tool, compared with other hard alloy cutters, along with suitable cutting data will greatly improve the production efficiency and product quality, it can completely meet the process of nimonic super alloy GH2312.

An Experimental Study of Cutting Performances of Worn Picks

NASA Astrophysics Data System (ADS)

Dogruoz, Cihan; Bolukbasi, Naci; Rostami, Jamal; Acar, Cemil

2016-01-01

The best means to assess rock cuttability and efficiency of cutting process for using mechanical excavation is specific energy (SE), measured in full-scale rock cutting test. This is especially true for the application of roadheaders, often fitted with drag-type cutting tools. Radial picks or drag bits are changed during the operation as they reach a certain amount of wear and become blunt. In this study, full-scale cutting tests in different sedimentary rock types with bits having various degree of wear were used to evaluate the influence of bit wear on cutting forces and specific energy. The relationship between the amount of wear as represented by the size of the wear flats at the tip of the bit, and cutting forces as well as specific energy was examined. The influence of various rock properties such as mineral content, uniaxial compressive strength, tensile strength, indentation index, shore hardness, Schmidt hammer hardness, and density with required SE of cutting using different levels of tool wear was also studied. The preliminary analysis of the data shows that the mean cutting forces increase 2-3 times and SE by 4-5 times when cutting with 4 mm wear flat as compared to cutting with new or sharp wedge shape bits. The grain size distribution of the muck for cutting different rock types and different level of bit wear was analyzed and discussed. The best fit prediction models for SE based on statistical analysis of laboratory test results are introduced. The model can be used for estimating the performance of mechanical excavators using radial tools, especially roadheaders, continuous miners and longwall drum shearers.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sherman, S.J.

The scope of this document is to define a test plan for the testing of the ASEA 60/2 industrial robot at the Bardons and Oliver (B and O) cut-off lathe in Plant 6. This test plan describes the administrative procedures to be used and the general responsibilities of the Westinghouse Materials Company of Ohio (WMCO) organizations which are most involved in the preparation, coordination, and conduct of the installation, startup, and testing. Any deviations to this procedure will be approved by the test coordinator, Manager, Development, and Plant 6 Supervisor. The purpose of this test is to evaluate the ASEAmore » 60/2 industrial robot to determine the feasibility of implementing a robot at the Bardons and Oliver cut-off lathe in Plant 6 for material handling purposes. This robot will be used as a developmental robot in that it will be installed temporarily at the B and O and then be relocated to another application. The robot will be used for training purposes to familiarize personnel with programming, computer usage, maintenance, and operation of the robot. Radiation exposure reduction of the machine tool operators in Plant 6 will also be determined. Success of the testing will be measured by the amount of radiation exposure reduction and determining the complexity of incorporating automated machinery with the B and O cut-off lathe utilizing a robot.« less

Diagnosis of edge condition based on force measurement during milling of composites

NASA Astrophysics Data System (ADS)

Felusiak, Agata; Twardowski, Paweł

2018-04-01

The present paper presents comparative results of the forecasting of a cutting tool wear with the application of different methods of diagnostic deduction based on the measurement of cutting force components. The research was carried out during the milling of the Duralcan F3S.10S aluminum-ceramic composite. Prediction of the toolwear was based on one variable, two variables regression Multilayer Perceptron(MLP)and Radial Basis Function(RBF)neural networks. Forecasting the condition of the cutting tool on the basis of cutting forces has yielded very satisfactory results.

Tool path strategy and cutting process monitoring in intelligent machining

NASA Astrophysics Data System (ADS)

Chen, Ming; Wang, Chengdong; An, Qinglong; Ming, Weiwei

2018-06-01

Intelligent machining is a current focus in advanced manufacturing technology, and is characterized by high accuracy and efficiency. A central technology of intelligent machining—the cutting process online monitoring and optimization—is urgently needed for mass production. In this research, the cutting process online monitoring and optimization in jet engine impeller machining, cranio-maxillofacial surgery, and hydraulic servo valve deburring are introduced as examples of intelligent machining. Results show that intelligent tool path optimization and cutting process online monitoring are efficient techniques for improving the efficiency, quality, and reliability of machining.

From Interfaces to Bulk: Experimental-Computational Studies Across Time and Length Scales of Multi-Functional Ionic Polymers

DOE Office of Scientific and Technical Information (OSTI.GOV)

Perahia, Dvora; Grest, Gary S.

Neutron experiments coupled with computational components have resulted in unprecedented understanding of the factors that impact the behavior of ionic structured polymers. Additionally, new computational tools to study macromolecules, were developed. In parallel, this DOE funding have enabled the education of the next generation of material researchers who are able to take the advantage neutron tools offer to the understanding and design of advanced materials. Our research has provided unprecedented insight into one of the major factors that limits the use of ionizable polymers, combining the macroscopic view obtained from the experimental techniques with molecular insight extracted from computational studiesmore » leading to transformative knowledge that will impact the design of nano-structured, materials. With the focus on model systems, of broad interest to the scientific community and to industry, the research addressed challenges that cut across a large number of polymers, independent of the specific chemical structure or the transported species.« less

Improved Mechanical and Tribological Properties of Metal-Matrix Composites Dispersion-Strengthened by Nanoparticles 

PubMed Central

Levashov, Evgenii; Kurbatkina, Victoria; Alexandr, Zaytsev

2009-01-01

Co- and Fe-based alloys produced by powder technology are being widely used as a matrix for diamond-containing composites in cutting, drilling, grinding pplications, etc. The severe service conditions demand that the mechanical and tribological properties of these alloys be improved. Development of metal-matrix composites (MMCs) and alloys reinforced with nanoparticles is a promising way to resolve this problem. In this work, we have investigated the effect of nano-sized WC, ZrO2, Al2O3, and Si3N4 additives on the properties of sintered dispersion-strengthened Co- and Fe-based MMCs. The results show an increase in the hardness (up to 10 HRB), bending strength (up to 50%), wear resistance (by a factor of 2–10) and a decrease in the friction coefficient (up to 4-fold) of the dispersion-strengthened materials. The use of designed alloys as a binder of cutting diamond tools gave a 4-fold increment in the service life, without reduction in their cutting speed.

75 FR 34179 - Tivoly, Inc., Derby Line, VT; Notice of Negative Determination on Reconsideration

Federal Register 2010, 2011, 2012, 2013, 2014

2010-06-16

... firm regarding their purchases of cutting tools, taps, and reamers during 2007, 2008, and during the... five months in 2008. Those surveys showed customer imports of cutting tools, taps, and reamers to be...

Developing Lathing Parameters for PBX 9501

DOE Office of Scientific and Technical Information (OSTI.GOV)

Woodrum, Randall Brock

This thesis presents the work performed on lathing PBX 9501 to gather and analyze cutting force and temperature data during the machining process. This data will be used to decrease federal-regulation-constrained machining time of the high explosive PBX 9501. The effects of machining parameters depth of cut, surface feet per minute, and inches per revolution on cutting force and cutting interface were evaluated. Cutting tools of tip radius 0.005 -inches and 0.05 -inches were tested to determine what effect the tool shape had on the machining process as well. A consistently repeatable relationship of temperature to changing depth of cutmore » and surface feet per minute is found, while only a weak dependence was found to changing inches per revolution. Results also show the relation of cutting force to depth of cut and inches per revolution, while weak dependence on SFM is found. Conclusions suggest rapid, shallow cuts optimize machining time for a billet of PBX 9501, while minimizing temperature increase and cutting force.« less

Theoretical and experimental research on machine tool servo system for ultra-precision position compensation on CNC lathe

NASA Astrophysics Data System (ADS)

Ma, Zhichao; Hu, Leilei; Zhao, Hongwei; Wu, Boda; Peng, Zhenxing; Zhou, Xiaoqin; Zhang, Hongguo; Zhu, Shuai; Xing, Lifeng; Hu, Huang

2010-08-01

The theories and techniques for improving machining accuracy via position control of diamond tool's tip and raising resolution of cutting depth on precise CNC lathes have been extremely focused on. A new piezo-driven ultra-precision machine tool servo system is designed and tested to improve manufacturing accuracy of workpiece. The mathematical model of machine tool servo system is established and the finite element analysis is carried out on parallel plate flexure hinges. The output position of diamond tool's tip driven by the machine tool servo system is tested via a contact capacitive displacement sensor. Proportional, integral, derivative (PID) feedback is also implemented to accommodate and compensate dynamical change owing cutting forces as well as the inherent non-linearity factors of the piezoelectric stack during cutting process. By closed loop feedback controlling strategy, the tracking error is limited to 0.8 μm. Experimental results have shown the proposed machine tool servo system could provide a tool positioning resolution of 12 nm, which is much accurate than the inherent CNC resolution magnitude. The stepped shaft of aluminum specimen with a step increment of cutting depth of 1 μm is tested, and the obtained contour illustrates the displacement command output from controller is accurately and real-time reflected on the machined part.

Limitations Of The Current State Space Modelling Approach In Multistage Machining Processes Due To Operation Variations

NASA Astrophysics Data System (ADS)

Abellán-Nebot, J. V.; Liu, J.; Romero, F.

2009-11-01

The State Space modelling approach has been recently proposed as an engineering-driven technique for part quality prediction in Multistage Machining Processes (MMP). Current State Space models incorporate fixture and datum variations in the multi-stage variation propagation, without explicitly considering common operation variations such as machine-tool thermal distortions, cutting-tool wear, cutting-tool deflections, etc. This paper shows the limitations of the current State Space model through an experimental case study where the effect of the spindle thermal expansion, cutting-tool flank wear and locator errors are introduced. The paper also discusses the extension of the current State Space model to include operation variations and its potential benefits.

The use of power tools in the insertion of cortical bone screws.

PubMed

Elliott, D

1992-01-01

Cortical bone screws are commonly used in fracture surgery, most patterns are non-self-tapping and require a thread to be pre-cut. This is traditionally performed using hand tools rather than their powered counterparts. Reasons given usually imply that power tools are more dangerous and cut a less precise thread, but there is no evidence to support this supposition. A series of experiments has been performed which show that the thread pattern cut with either method is identical and that over-penetration with the powered tap is easy to control. The conclusion reached is that both methods produce consistently reliable results but use of power tools is much faster.

The Generation Rate of Respirable Dust from Cutting Fiber Cement Siding Using Different Tools

PubMed Central

Qi, Chaolong; Echt, Alan; Gressel, Michael G

2017-01-01

This article describes the evaluation of the generation rate of respirable dust (GAPS, defined as the mass of respirable dust generated per unit linear length cut) from cutting fiber cement siding using different tools in a laboratory testing system. We used an aerodynamic particle sizer spectrometer (APS) to continuously monitor the real-time size distributions of the dust throughout cutting tests when using a variety of tools, and calculated the generation rate of respirable dust for each testing condition using the size distribution data. The test result verifies that power shears provided an almost dust-free operation with a GAPS of 0.006 gram meter−1 (g m−1) at the testing condition. For the same power saws, the cuts using saw blades with more teeth generated more respirable dusts. Using the same blade for all four miter saws tested in this study, a positive linear correlation was found between the saws’ blade rotating speed and its dust generation rate. In addition, a circular saw running at the highest blade rotating speed of 9068 RPM generated the greatest amount of dust. All the miter saws generated less dust in the ‘chopping mode’ than in the ‘chopping and sliding’ mode. For the tested saws, GAPS consistently decreased with the increases of the saw cutting feed rate and the number of board in the stack. All the test results point out that fewer cutting interactions between the saw blade’s teeth and the siding board for a unit linear length of cut tend to result in a lower generation rate of respirable dust. These results may help guide optimal operation in practice and future tool development aimed at minimizing dust generation while producing a satisfactory cut. PMID:28395343

The Generation Rate of Respirable Dust from Cutting Fiber Cement Siding Using Different Tools.

PubMed

Qi, Chaolong; Echt, Alan; Gressel, Michael G

2017-03-01

This article describes the evaluation of the generation rate of respirable dust (GAPS, defined as the mass of respirable dust generated per unit linear length cut) from cutting fiber cement siding using different tools in a laboratory testing system. We used an aerodynamic particle sizer spectrometer (APS) to continuously monitor the real-time size distributions of the dust throughout cutting tests when using a variety of tools, and calculated the generation rate of respirable dust for each testing condition using the size distribution data. The test result verifies that power shears provided an almost dust-free operation with a GAPS of 0.006 g m-1 at the testing condition. For the same power saws, the cuts using saw blades with more teeth generated more respirable dusts. Using the same blade for all four miter saws tested in this study, a positive linear correlation was found between the saws' blade rotating speed and its dust generation rate. In addition, a circular saw running at the highest blade rotating speed of 9068 rpm generated the greatest amount of dust. All the miter saws generated less dust in the 'chopping mode' than in the 'chopping and sliding' mode. For the tested saws, GAPS consistently decreased with the increases of the saw cutting feed rate and the number of board in the stack. All the test results point out that fewer cutting interactions between the saw blade's teeth and the siding board for a unit linear length of cut tend to result in a lower generation rate of respirable dust. These results may help guide optimal operation in practice and future tool development aimed at minimizing dust generation while producing a satisfactory cut. Published by Oxford University Press on behalf of The British Occupational Hygiene Society 2017.

Properties and Cutting Performance of TiAlSiN Coating Prepared by Cathode Arc Ion Plating

NASA Astrophysics Data System (ADS)

Zhang, Er-Geng; Chen, Qiang; Wang, Qin-Xue; Huang, Biao

2016-06-01

TiAlSiN coating was deposited on high-speed steel (HSS) samples and cemented carbide tool inserts, respectively, by a new coating preparation procedure, and its properties and cutting performance were characterized. The coating thickness, chemical composition, microstructure morphology and mechanical properties were investigated by X-ray fluorescence measurement system, energy dispersive spectrometer (EDS), scanning electron microscope (SEM), nanoindentation, Rockwell hardness tester and ball-on-disc tribometer. A 3D orthogonal cutting experiment model was established by DEFORM-3D to study the influences of different coating thicknesses on cutting force and temperature, and the field cutting experiment was carried out. The results show that the thickness of TiAlSiN coating is 3.14μm prepared by the 3μm preparation procedure, microhardness is 36.727GPa with the Si content of about 5.22at.% as well as good fracture toughness and adhesion strength. The TC4 and AISI 1045 cutting tool inserts with 4μm coating thickness have the minimum cutting forces of about 734.7N and 450.7N, respectively. Besides, tool inserts with a thickness of 3μm have the minimum cutting temperatures of about 510.2∘C and 230.6∘C, respectively.

Ultrafast Bessel beams: advanced tools for laser materials processing

NASA Astrophysics Data System (ADS)

Stoian, Razvan; Bhuyan, Manoj K.; Zhang, Guodong; Cheng, Guanghua; Meyer, Remy; Courvoisier, Francois

2018-05-01

Ultrafast Bessel beams demonstrate a significant capacity of structuring transparent materials with a high degree of accuracy and exceptional aspect ratio. The ability to localize energy on the nanometer scale (bypassing the 100-nm milestone) makes them ideal tools for advanced laser nanoscale processing on surfaces and in the bulk. This allows to generate and combine micron and nano-sized features into hybrid structures that show novel functionalities. Their high aspect ratio and the accurate location can equally drive an efficient material modification and processing strategy on large dimensions. We review, here, the main concepts of generating and using Bessel non-diffractive beams and their remarkable features, discuss general characteristics of their interaction with matter in ablation and material modification regimes, and advocate their use for obtaining hybrid micro and nanoscale structures in two and three dimensions (2D and 3D) performing complex functions. High-throughput applications are indicated. The example list ranges from surface nanostructuring and laser cutting to ultrafast laser welding and the fabrication of 3D photonic systems embedded in the volume.

Cut-laceration injuries and related career groups in New Jersey career, vocational, and technical education courses and programs.

PubMed

Shendell, Derek G; Mizan, Samina S; Marshall, Elizabeth G; Kelly, Sarah W; Therkorn, Jennifer H; Campbell, Jennifer K; Miller, Ashley E

2012-09-01

Investigations of young workers, including limited surveys in supervised school settings, suggested their elevated injury risk. This study identified factors contributing to cuts-lacerations among adolescents in New Jersey secondary school career, technical, and vocational education programs. Of 1,772 injuries reported between December 1, 1998, and September 1, 2010, 777 (44%) were cuts-lacerations; analyses focused on 224 reports (n = 182 post-exclusions) submitted after fall 2005 in three career groups-Food, Hospitality & Tourism (FH&T) (n = 71), Manufacturing & Construction (M&C) (n = 84), and Automotive & Transportation (A&T) (n = 27). Most students were "struck by" tools or hard surfaces (n = 93, 51%); 63 cuts were from knives in FH&T. In M&C, most cuts-lacerations were caused by hand-held tools (n = 18) and being "struck against/by" or "caught between hard surfaces" (n = 19). Males reported more cuts-lacerations (n = 145), most commonly among 11th graders (n = 54) and ages 16 to 17 years (n = 79). Fingers (n = 117) were most often injured, usually by cutting tools (n = 83). Training, supervision, and appropriate equipment, and further assessments of "struck by" and "pinch point" hazards, are needed. Copyright 2012, SLACK Incorporated.

Wear behavior of carbide tool coated with Yttria-stabilized zirconia nano particles.

NASA Astrophysics Data System (ADS)

Jadhav, Pavandatta M.; Reddy, Narala Suresh Kumar

2018-04-01

Wear mechanism takes predominant role in reducing the tool life during machining of Titanium alloy. Challenges of wear mechanisms such as variation in chip, high pressure loads and spring back are responsible for tool wear. In addition, many tool materials are inapt for machining due to low thermal conductivity and volume specific heat of these materials results in high cutting temperature during machining. To confront this issue Electrostatic Spray Coating (ESC) coating technique is utilized to enhance the tool life to an acceptable level. The Yttria Stabilized Zirconia (YSZ) acts as a thermal barrier coating having high thermal expansion coefficient and thermal shock resistance. This investigation focuses on the influence of YSZ nanocoating on the tungsten carbide tool material and improve the machinability of Ti-6Al-4V alloy. YSZ nano powder was coated on the tungsten carbide pin by using ESC technique. The coatings have been tested for wear and friction behavior by using a pin-on-disc tribological tester. The dry sliding wear test was performed on Titanium alloy (Ti-6Al-4V) disc and YSZ coated tungsten carbide (pin) at ambient atmosphere. The performance parameters like wear rate and temperature rise were considered upon performing the dry sliding test on Ti-6Al-4V alloy disc. The performance parameters were calculated by using coefficient of friction and frictional force values which were obtained from the pin on disc test. Substantial resistance to wear was achieved by the coating.

Surface Finish and Residual Stresses Induced by Orthogonal Dry Machining of AA7075-T651

PubMed Central

Jomaa, Walid; Songmene, Victor; Bocher, Philippe

2014-01-01

The surface finish was extensively studied in usual machining processes (turning, milling, and drilling). For these processes, the surface finish is strongly influenced by the cutting feed and the tool nose radius. However, a basic understanding of tool/surface finish interaction and residual stress generation has been lacking. This paper aims to investigate the surface finish and residual stresses under the orthogonal cutting since it can provide this information by avoiding the effect of the tool nose radius. The orthogonal machining of AA7075-T651 alloy through a series of cutting experiments was performed under dry conditions. Surface finish was studied using height and amplitude distribution roughness parameters. SEM and EDS were used to analyze surface damage and built-up edge (BUE) formation. An analysis of the surface topography showed that the surface roughness was sensitive to changes in cutting parameters. It was found that the formation of BUE and the interaction between the tool edge and the iron-rich intermetallic particles play a determinant role in controlling the surface finish during dry orthogonal machining of the AA7075-T651 alloy. Hoop stress was predominantly compressive on the surface and tended to be tensile with increased cutting speed. The reverse occurred for the surface axial stress. The smaller the cutting feed, the greater is the effect of cutting speed on both axial and hoop stresses. By controlling the cutting speed and feed, it is possible to generate a benchmark residual stress state and good surface finish using dry machining. PMID:28788534

Monitoring machining conditions by infrared images

NASA Astrophysics Data System (ADS)

Borelli, Joao E.; Gonzaga Trabasso, Luis; Gonzaga, Adilson; Coelho, Reginaldo T.

2001-03-01

During machining process the knowledge of the temperature is the most important factor in tool analysis. It allows to control main factors that influence tool use, life time and waste. The temperature in the contact area between the piece and the tool is resulting from the material removal in cutting operation and it is too difficult to be obtained because the tool and the work piece are in motion. One way to measure the temperature in this situation is detecting the infrared radiation. This work presents a new methodology for diagnosis and monitoring of machining processes with the use of infrared images. The infrared image provides a map in gray tones of the elements in the process: tool, work piece and chips. Each gray tone in the image corresponds to a certain temperature for each one of those materials and the relationship between the gray tones and the temperature is gotten by the previous of infrared camera calibration. The system developed in this work uses an infrared camera, a frame grabber board and a software composed of three modules. The first module makes the image acquisition and processing. The second module makes the feature image extraction and performs the feature vector. Finally, the third module uses fuzzy logic to evaluate the feature vector and supplies the tool state diagnostic as output.

Applications of picosecond lasers and pulse-bursts in precision manufacturing

NASA Astrophysics Data System (ADS)

Knappe, Ralf

2012-03-01

Just as CW and quasi-CW lasers have revolutionized the materials processing world, picosecond lasers are poised to change the world of micromachining, where lasers outperform mechanical tools due to their flexibility, reliability, reproducibility, ease of programming, and lack of mechanical force or contamination to the part. Picosecond lasers are established as powerful tools for micromachining. Industrial processes like micro drilling, surface structuring and thin film ablation benefit from a process, which provides highest precision and minimal thermal impact for all materials. Applications such as microelectronics, semiconductor, and photovoltaic industries use picosecond lasers for maximum quality, flexibility, and cost efficiency. The range of parts, manufactured with ps lasers spans from microscopic diamond tools over large printing cylinders with square feet of structured surface. Cutting glass for display and PV is a large application, as well. With a smart distribution of energy into groups of ps-pulses at ns-scale separation (known as burst mode) ablation rates can be increased by one order of magnitude or more for some materials, also providing a better surface quality under certain conditions. The paper reports on the latest results of the laser technology, scaling of ablation rates, and various applications in ps-laser micromachining.

Powder-Collection System for Ultrasonic/Sonic Drill/Corer

NASA Technical Reports Server (NTRS)

Sherrit, Stewart; Bar-Cohen, Yoseph; Bao, Xiaoqi; Chang, Zensheu; Blake, David; Bryson, Charles

2005-01-01

A system for collecting samples of powdered rock has been devised for use in conjunction with an ultrasonic/sonic drill/corer (USDC) -- a lightweight, lowpower apparatus designed to cut into, and acquire samples of, rock or other hard material for scientific analysis. The USDC includes a drill bit, corer, or other tool bit, in which ultrasonic and sonic vibrations are excited by an electronically driven piezoelectric actuator. The USDC advances into the rock or other material of interest by means of a hammering action and a resulting chiseling action at the tip of the tool bit. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, a negligible amount of axial force is needed to make the USDC advance into the material. Also unlike a conventional twist drill, the USDC operates without need for torsional restraint, lubricant, or a sharp bit. The USDC generates powder as a byproduct of the drilling or coring process. The purpose served by the present samplecollection system is to remove the powder from the tool-bit/rock interface and deliver the powder to one or more designated location(s) for analysis or storage

Augmented Endoscopic Images Overlaying Shape Changes in Bone Cutting Procedures.

PubMed

Nakao, Megumi; Endo, Shota; Nakao, Shinichi; Yoshida, Munehito; Matsuda, Tetsuya

2016-01-01

In microendoscopic discectomy for spinal disorders, bone cutting procedures are performed in tight spaces while observing a small portion of the target structures. Although optical tracking systems are able to measure the tip of the surgical tool during surgery, the poor shape information available during surgery makes accurate cutting difficult, even if preoperative computed tomography and magnetic resonance images are used for reference. Shape estimation and visualization of the target structures are essential for accurate cutting. However, time-varying shape changes during cutting procedures are still challenging issues for intraoperative navigation. This paper introduces a concept of endoscopic image augmentation that overlays shape changes to support bone cutting procedures. This framework handles the history of the location of the measured drill tip as a volume label and visualizes the remains to be cut overlaid on the endoscopic image in real time. A cutting experiment was performed with volunteers, and the feasibility of this concept was examined using a clinical navigation system. The efficacy of the cutting aid was evaluated with respect to the shape similarity, total moved distance of a cutting tool, and required cutting time. The results of the experiments showed that cutting performance was significantly improved by the proposed framework.

Optical Spectroscopy of New Materials

NASA Technical Reports Server (NTRS)

White, Susan M.; Arnold, James O. (Technical Monitor)

1993-01-01

Composites are currently used for a rapidly expanding number of applications including aircraft structures, rocket nozzles, thermal protection of spacecraft, high performance ablative surfaces, sports equipment including skis, tennis rackets and bicycles, lightweight automobile components, cutting tools, and optical-grade mirrors. Composites are formed from two or more insoluble materials to produce a material with superior properties to either component. Composites range from dispersion-hardened alloys to advanced fiber-reinforced composites. UV/VIS and FTIR spectroscopy currently is used to evaluate the bonding between the matrix and the fibers, monitor the curing process of a polymer, measure surface contamination, characterize the interphase material, monitor anion transport in polymer phases, characterize the void formation (voids must be minimized because, like cracks in a bulk material, they lead to failure), characterize the surface of the fiber component, and measure the overall optical properties for energy balances.

Analysis of Surface and Subsurface Damage Morphology in Rotary Ultrasonic Machining of BK7 Glass

NASA Astrophysics Data System (ADS)

Hong-xiang, Wang; Chu, Wang; Jun-liang, Liu; Shi, Gao; Wen-Jie, Zhai

2017-11-01

This paper investigates the formation process of surface/subsurface damage in the rotary ultrasonic machining of BK7 glass. The results show that during the milling using the end face of the tool, the cutting depth and the residual height between the abrasive grains constantly change with the high-frequency vibration, generating lots of cracks on both sides of the scratches. The high-frequency vibration accelerates the chips falling from the surface, so that the chips and thermal damage are reduced, causing the grinding surface quality better. A plastic deformation area is formed during the grinding, due to the non-uniform cutting force on the material surface, and the residual stress is produced in the deformation area, inducing the median/lateral cracks.

A rotational ablation tool for calcified atherosclerotic plaque removal.

PubMed

Kim, Min-Hyeng; Kim, Hyung-Jung; Kim, Nicholas N; Yoon, Hae-Sung; Ahn, Sung-Hoon

2011-12-01

Atherosclerosis is a major cardiovascular disease involving accumulations of lipids, white blood cells, and other materials on the inside of artery walls. Since the calcification found in the advanced stage of atherosclerosis dramatically enhances the mechanical properties of the plaque, restoring the original lumen of the artery remains a challenge. High-speed rotational atherectomy, when performed with an ablating grinder to remove the plaque, produces much better results in the treatment of calcified plaque compared to other methods. However, the high-speed rotation of the Rotablator commercial rotational atherectomy device produces microcavitation, which should be avoided because of the serious complications it can cause. This research involves the development of a high-speed rotational ablation tool that does not generate microcavitation. It relies on surface modification to achieve the required surface roughness. The surface roughness of the tool for differential cutting was designed based on lubrication theory, and the surface of the tool was modified using Nd:YAG laser beam engraving. Electron microscope images and profiles indicated that the engraved surface of the tool had approximately 1 μm of root mean square surface roughness. The ablation experiment was performed on hydroxyapatite/polylactide composite with an elastic modulus similar to that of calcified plaque. In addition, differential cutting was verified on silicone rubber with an elastic modulus similar to that of a normal artery. The tool performance and reliability were evaluated by measuring the ablation force exerted, the size of the debris generated during ablation, and through visual inspection of the silicone rubber surface.

Video segmentation for post-production

NASA Astrophysics Data System (ADS)

Wills, Ciaran

2001-12-01

Specialist post-production is an industry that has much to gain from the application of content-based video analysis techniques. However the types of material handled in specialist post-production, such as television commercials, pop music videos and special effects are quite different in nature from the typical broadcast material which many video analysis techniques are designed to work with; shots are short and highly dynamic, and the transitions are often novel or ambiguous. We address the problem of scene change detection and develop a new algorithm which tackles some of the common aspects of post-production material that cause difficulties for past algorithms, such as illumination changes and jump cuts. Operating in the compressed domain on Motion JPEG compressed video, our algorithm detects cuts and fades by analyzing each JPEG macroblock in the context of its temporal and spatial neighbors. Analyzing the DCT coefficients directly we can extract the mean color of a block and an approximate detail level. We can also perform an approximated cross-correlation between two blocks. The algorithm is part of a set of tools being developed to work with an automated asset management system designed specifically for use in post-production facilities.

USSR Report, Machine Tools and Metalworking Equipment, No. 6

DTIC Science & Technology

1983-05-18

production output per machine tool at a tool plant average 2-3 times the figures for tool shops. This is explained by the well-known advantages of...specialized production. Specifically, the advantages of standardization and unification of machine- attachment design can be fully exploited in...lemiiiiä IS MVCti\\e UtiUzation °f appropriate special equipmeT ters)! million thread-cutting dies, and 2.3 million milling cut- The advantages of

Tool Wear Monitoring Using Time Series Analysis

NASA Astrophysics Data System (ADS)

Song, Dong Yeul; Ohara, Yasuhiro; Tamaki, Haruo; Suga, Masanobu

A tool wear monitoring approach considering the nonlinear behavior of cutting mechanism caused by tool wear and/or localized chipping is proposed, and its effectiveness is verified through the cutting experiment and actual turning machining. Moreover, the variation in the surface roughness of the machined workpiece is also discussed using this approach. In this approach, the residual error between the actually measured vibration signal and the estimated signal obtained from the time series model corresponding to dynamic model of cutting is introduced as the feature of diagnosis. Consequently, it is found that the early tool wear state (i.e. flank wear under 40µm) can be monitored, and also the optimal tool exchange time and the tool wear state for actual turning machining can be judged by this change in the residual error. Moreover, the variation of surface roughness Pz in the range of 3 to 8µm can be estimated by the monitoring of the residual error.

Estimation of tool wear during CNC milling using neural network-based sensor fusion

NASA Astrophysics Data System (ADS)

Ghosh, N.; Ravi, Y. B.; Patra, A.; Mukhopadhyay, S.; Paul, S.; Mohanty, A. R.; Chattopadhyay, A. B.

2007-01-01

Cutting tool wear degrades the product quality in manufacturing processes. Monitoring tool wear value online is therefore needed to prevent degradation in machining quality. Unfortunately there is no direct way of measuring the tool wear online. Therefore one has to adopt an indirect method wherein the tool wear is estimated from several sensors measuring related process variables. In this work, a neural network-based sensor fusion model has been developed for tool condition monitoring (TCM). Features extracted from a number of machining zone signals, namely cutting forces, spindle vibration, spindle current, and sound pressure level have been fused to estimate the average flank wear of the main cutting edge. Novel strategies such as, signal level segmentation for temporal registration, feature space filtering, outlier removal, and estimation space filtering have been proposed. The proposed approach has been validated by both laboratory and industrial implementations.

Rock Cutting Depth Model Based on Kinetic Energy of Abrasive Waterjet

NASA Astrophysics Data System (ADS)

Oh, Tae-Min; Cho, Gye-Chun

2016-03-01

Abrasive waterjets are widely used in the fields of civil and mechanical engineering for cutting a great variety of hard materials including rocks, metals, and other materials. Cutting depth is an important index to estimate operating time and cost, but it is very difficult to predict because there are a number of influential variables (e.g., energy, geometry, material, and nozzle system parameters). In this study, the cutting depth is correlated to the maximum kinetic energy expressed in terms of energy (i.e., water pressure, water flow rate, abrasive feed rate, and traverse speed), geometry (i.e., standoff distance), material (i.e., α and β), and nozzle system parameters (i.e., nozzle size, shape, and jet diffusion level). The maximum kinetic energy cutting depth model is verified with experimental test data that are obtained using one type of hard granite specimen for various parameters. The results show a unique curve for a specific rock type in a power function between cutting depth and maximum kinetic energy. The cutting depth model developed here can be very useful for estimating the process time when cutting rock using an abrasive waterjet.

Innovation Study for Laser Cutting of Complex Geometries with Paper Materials

NASA Astrophysics Data System (ADS)

Happonen, A.; Stepanov, A.; Piili, H.; Salminen, A.

Even though technology for laser cutting of paper materials has existed for over 30 years, it seems that results of applications of this technology and possibilities of laser cutting systems are not easily available. The aim of this study was to analyze the feasibility of the complex geometry laser cutting of paper materials and to analyze the innovation challenges and potential of current laser cutting technologies offer. This research studied the potential and possible challenges in applying CO2 laser cutting technology for cutting of paper materials in current supply chains trying to fulfil the changing needs of customer in respect of shape, fast response during rapid delivery cycle. The study is focused on examining and analyzing the different possibilities of laser cutting of paper material in application area of complex low volume geometry cutting. The goal of this case was to analyze the feasibility of the laser cutting from technical, quality and implementation points of view and to discuss availability of new business opportunities. It was noticed that there are new business models still available within laser technology applications in complex geometry cutting. Application of laser technology, in business-to-consume markets, in synergy with Internet service platforms can widen the customer base and offer new value streams for technology and service companies. Because of this, existing markets and competition has to be identified, and appropriate new and innovative business model needs to be developed. And to be competitive in the markets, models like these need to include the earning logic and the stages from production to delivery as discussed in the paper.

Investigations on Surface Milling of Hardened AISI 4140 Steel with Pulse Jet MQL Applicator

NASA Astrophysics Data System (ADS)

Bashir, Mahmood Al; Mia, Mozammel; Dhar, Nikhil Ranjan

2018-06-01

In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

Investigations on Surface Milling of Hardened AISI 4140 Steel with Pulse Jet MQL Applicator

NASA Astrophysics Data System (ADS)

Bashir, Mahmood Al; Mia, Mozammel; Dhar, Nikhil Ranjan

2016-06-01

In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

Study on super-long deep-hole drilling of titanium alloy.

PubMed

Liu, Zhanfeng; Liu, Yanshu; Han, Xiaolan; Zheng, Wencui

2018-01-01

In this study, the super-long deep-hole drilling of a titanium alloy was investigated. According to material properties of the titanium alloy, an experimental approach was designed to study three issues discovered during the drilling process: the hole-axis deflection, chip morphology, and tool wear. Based on the results of drilling experiments, crucial parameters for the super-long deep-hole drilling of titanium alloys were obtained, and the influences of these parameters on quality of the alloy's machining were also evaluated. Our results suggest that the developed drilling process is an effective method to overcome the challenge of super-long deep-hole drilling on difficult-to-cut materials.

Physical Modeling of Contact Processes on the Cutting Tools Surfaces of STM When Turning

NASA Astrophysics Data System (ADS)

Belozerov, V. A.; Uteshev, M. H.

2016-08-01

This article describes how to create an optimization model of the process of fine turning of superalloys and steel tools from STM on CNC machines, flexible manufacturing units (GPM), machining centers. Creation of the optimization model allows you to link (unite) contact processes simultaneously on the front and back surfaces of the tool from STM to manage contact processes and the dynamic strength of the cutting tool at the top of the STM. Established optimization model of management of the dynamic strength of the incisors of the STM in the process of fine turning is based on a previously developed thermomechanical (physical, heat) model, which allows the system thermomechanical approach to choosing brands STM (domestic and foreign) for cutting tools from STM designed for fine turning of heat resistant alloys and steels.

Laser circular cutting of Kevlar sheets: Analysis of thermal stress filed and assessment of cutting geometry

NASA Astrophysics Data System (ADS)

Yilbas, B. S.; Akhtar, S. S.; Karatas, C.

2017-11-01

A Kevlar laminate has negative thermal expansion coefficient, which makes it difficult to machine at room temperaures using the conventional cutting tools. Contararily, laser machining of a Kevlar laminate provides advantages over the conventional methods because of the non-mechanical contact between the cutting tool and the workpiece. In the present study, laser circular cutting of Kevlar laminate is considered. The experiment is carried out to examine and evaluate the cutting sections. Temperature and stress fields formed in the cutting section are simulated in line with the experimental study. The influence of hole diameters on temperature and stress fields are investigated incorporating two different hole diameters. It is found that the Kevlar laminate cutting section is free from large size asperities such as large scale sideways burnings and attachemnt of charred residues. The maximum temperature along the cutting circumference remains higher for the large diameter hole than that of the small diameter hole. Temperature decay is sharp around the cutting section in the region where the cutting terminates. This, in turn, results in high temperature gradients and the thermal strain in the cutting region. von Mises stress remains high in the region where temperature gradients are high. von Mises stress follows similar to the trend of temperature decay around the cutting edges.

Cutting process simulation of flat drill

NASA Astrophysics Data System (ADS)

Tamura, Shoichi; Matsumura, Takashi

2018-05-01

Flat drills at a point angle of 180 deg. have recently been developed for drilling of automobile parts with the inclination of the workpiece surfaces. The paper studies the cutting processes of the flat drills in the analytical simulation. A predictive force model is applied to simulation of the cutting force with the chip flow direction. The chip flow model is piled up with orthogonal cuttings in the plane containing the cutting velocities and the chip flow velocities, in which the chip flow direction is determined to minimize the cutting energy. Then, the cutting force is predicted in the determined in the chip flow model. The typical cutting force of the flat drill is discussed with comparing to that of the standard drill. The typical differences are confirmed in the cutting force change during the tool engagement and disengagement. The cutting force, then, is simulated in drilling for an inclined workpiece with a flat drill. The horizontal components in the cutting forces are simulated with changing the inclination angle of the plate. The horizontal force component in the flat drilling is stable to be controlled in terms of the machining accuracy and the tool breakage.

Modified soldering iron speeds cutting of synthetic materials

NASA Technical Reports Server (NTRS)

Schafer, W. G., Jr.

1966-01-01

Modified soldering iron cuts large lots of synthetic materials economically without leaving frayed or jagged edges. The soldering iron is modified by machining an axial slot in its heating element tip and mounting a cutting disk in it. An alternate design has an axially threaded bore in the tip to permit the use of various shapes of cutting blades.

View of a stone age adze cutting tool floating freely in the flight deck.

NASA Technical Reports Server (NTRS)

1992-01-01

View of a stone age adze cutting tool floating freely in the forward flight deck and framed by the forward and side windows. On the Earth below, the big island of Hawaii can be seen through the window.

Graph-Cut Methods for Grain Boundary Segmentation (Preprint)

DTIC Science & Technology

2011-06-01

metals and metal alloys ) are among the strongest determinants of many material properties, such as mechanical strength or fracture resistance. In materials...cropped) Ni-based alloy image (a) using normalized cut (b) and ratio cut (c). Similar to normalized cut is the average-cut approach [11], where the...framework [2]. (a) (b) (c) Figure 3: Segmentation of a (cropped) Ni-based alloy image by optimal labeling. (a) Segmented grain bound- aries in a template

Advances in photonic MOEMS-MEMS device thinning and polishing

NASA Astrophysics Data System (ADS)

McAneny, James J.; Kennedy, Mark; McGroggan, Tom

2010-02-01

As devices continue to increase in density and complexity, ever more stringent specifications are placed on the wafer scale equipment manufacturers to produce higher quality and higher output. This results in greater investment and more resource being diverted into producing tools and processes which can meet the latest demanding criteria. Substrate materials employed in the fabrication process range from Silicon through InP and include GaAs, InSb and other optical networking or waveguide materials. With this diversity of substrate materials presented, controlling the geometries and surfaces grows progressively more challenging. This article highlights the key parameters which require close monitoring and control in order to produce highly precise wafers as part of the fabrication process. Several as cut and commercially available standard polished wafer materials were used in empirical trials to test tooling options in generating high levels of geometric control over the dimensions while producing high quality surface finishes. Specific attention was given to the measurement and control of: flatness; parallelism/TTV; surface roughness and final target thickness as common specifications required by the industry. By combining the process variables of: plate speed, download pressure, slurry flow rate and concentration, pad type and wafer travel path across the polish pad, the effect of altering these variables was recorded and analysed to realize the optimum process conditions for the materials under test. The results being then used to design improved methods and tooling for the thinning and polishing of photonic materials applied to MOEMS-MEMS device fabrication.

Nitinol laser cutting: microstructure and functional properties of femtosecond and continuous wave laser processing

NASA Astrophysics Data System (ADS)

Biffi, C. A.; Tuissi, A.

2017-03-01

Thermal processing can affect the properties of smart materials, and the correct selection of the best manufacturing technology is fundamental for producing high tech smart devices, containing embedded functional properties. In this work cutting of thin superelastic Nitinol plates using a femtosecond (fs) and continuous wave (CW) laser was studied. Diamond shaped elements were cut to characterize the kerf qualitative features; microstructural analysis of the cross sections allowed identification of thermal damage characteristics introduced into the material during the laser processes. A thermally undamaged microstructure was observed for fs laser cutting, while CW was seen to be characterized by a large heat-affected zone. Functional properties were investigated by differential scanning calorimetry and tensile testing of laser cut microelements and of the reference material. It was seen that the martensitic transformation behavior of Nitinol is not affected by fs regime, while cw cutting provokes an effect equivalent to a high temperature thermal treatment in the material surrounding the cutting kerf, degradating the material properties. Finally, tensile testing indicated that superelastic performances were guaranteed by fs regime, while strong reduction of the recoverable strain was detected in the CW processed sample.

Aqueous cutting fluid for machining fissionable materials

DOEpatents

Duerksen, Walter K.; Googin, John M.; Napier, Jr., Bradley

1984-01-01

The present invention is directed to a cutting fluid for machining fissionable material. The cutting fluid is formed of glycol, water and boron compound in an adequate concentration for effective neutron attenuation so as to inhibit criticality incidents during machining.

Chatter reduction in boring process by using piezoelectric shunt damping with experimental verification

NASA Astrophysics Data System (ADS)

Yigit, Ufuk; Cigeroglu, Ender; Budak, Erhan

2017-09-01

Chatter is a self-excited type of vibration that develops during machining due to process-structure dynamic interactions resulting in modulated chip thickness. Chatter is an important problem as it results in poor surface quality, reduced productivity and tool life. The stability of a cutting process is strongly influenced by the frequency response function (FRF) at the cutting point. In this study, the effect of piezoelectric shunt damping on chatter vibrations in a boring process is studied. In piezoelectric shunt damping method, an electrical impedance is connected to a piezoelectric transducer which is bonded on cutting tool. Electrical impedance of the circuit consisting of piezoceramic transducer and passive shunt is tuned to the desired natural frequency of the cutting tool in order to maximize damping. The optimum damping is achieved in analytical and finite element models (FEM) by using a genetic algorithm focusing on the real part of the tool point FRF rather than the amplitude. Later, a practical boring bar is considered where the optimum circuit parameters are obtained by the FEM. Afterwards, the effect of the optimized piezoelectric shunt damping on the dynamic rigidity and absolute stability limit of the cutting process are investigated experimentally by modal analysis and cutting tests. It is both theoretically and experimentally shown that application of piezoelectric shunt damping results in a significant increase in the absolute stability limit in boring operations.

Method and device for determining the position of a cutting tool relative to the rotational axis of a spindle-mounted workpiece

DOEpatents

Williams, R.R.

1980-09-03

The present invention is directed to a method and device for determining the location of a cutting tool with respect to the rotational axis of a spindle-mounted workpiece. A vacuum cup supporting a machinable sacrificial pin is secured to the workpiece at a location where the pin will project along and encompass the rotational axis of the workpiece. The pin is then machined into a cylinder. The position of the surface of the cutting tool contacting the machine cylinder is spaced from the rotational axis of the workpiece a distance equal to the radius of the cylinder.

Method and device for determining the position of a cutting tool relative to the rotational axis of a spindle-mounted workpiece

DOEpatents

Williams, Richard R.

1982-01-01

The present invention is directed to a method and device for determining the location of a cutting tool with respect to the rotational axis of a spindle-mounted workpiece. A vacuum cup supporting a machinable sacrifical pin is secured to the workpiece at a location where the pin will project along and encompass the rotational axis of the workpiece. The pin is then machined into a cylinder. The position of the surface of the cutting tool contacting the machine cylinder is spaced from the rotational aixs of the workpiece a distance equal to the radius of the cylinder.

The effect of cutting parameters on the performance of ZTA-MgO cutting tool

NASA Astrophysics Data System (ADS)

Ali, A. M.; Hamidon, N. E.; Zaki, N. K. M.; Mokhtar, S.; Azhar, A. Z. A.; Bahar, R.; Ahmad, Z. A.

2018-01-01

The effect of cutting parameters on the performances of ZTA-MgO ceramic cutting tool investigated. The aim of this project is to discover the effect of cutting speed and feedrate on the performance of the ZTA-MgO cutting tool via wear and surface roughness measurement. CNC turning machining performed using the cutting speed, Vc range from 354 to 471 m/min and the feed rate, f 0.1, 0.3 and 0.5 mm/rev while the depth of cut, d is kept constant at 0.2 mm. The flank wear, crater wear, and chipping were measured accordingly using optical microscope, Matlab programming and SEM. Surface roughness of machined stainless steel 316L surface were measured using the surface roughness tester (Mitutoyo MTR097-8. The result showing the increment trend of flank wear with increment of cutting speed and feed rate with the lowest value of flank wear, 0.061 mm achieved at Vc = 354 m/min and f = 0.1 mm/rev while the highest flank wear is 0.480 mm at Vc = 471 m/min and f = 0.5 mm/rev. The increasing pattern also observed in the crater wear results. The lowest area of crater wear is 2.2736 mm2 at Vc = 354 m/min and f = 0.1 mm/rev while the highest value is 4.8524 mm2 at Vc = 471 m/min and f = 0.5 mm/rev. As for the surface roughness, the higher the cutting speed, the lower the average roughness (Ra) value. Cutting speed, Vc = 471 m/min with f = 0.1 mm/rev has the lowest value of Ra which is 0.72µm.

Process Damping and Cutting Tool Geometry in Machining

NASA Astrophysics Data System (ADS)

Taylor, C. M.; Sims, N. D.; Turner, S.

2011-12-01

Regenerative vibration, or chatter, limits the performance of machining processes. Consequences of chatter include tool wear and poor machined surface finish. Process damping by tool-workpiece contact can reduce chatter effects and improve productivity. Process damping occurs when the flank (also known as the relief face) of the cutting tool makes contact with waves on the workpiece surface, created by chatter motion. Tool edge features can act to increase the damping effect. This paper examines how a tool's edge condition combines with the relief angle to affect process damping. An analytical model of cutting with chatter leads to a two-section curve describing how process damped vibration amplitude changes with surface speed for radiussed tools. The tool edge dominates the process damping effect at the lowest surface speeds, with the flank dominating at higher speeds. A similar curve is then proposed regarding tools with worn edges. Experimental data supports the notion of the two-section curve. A rule of thumb is proposed which could be useful to machine operators, regarding tool wear and process damping. The question is addressed, should a tool of a given geometry, used for a given application, be considered as sharp, radiussed or worn regarding process damping.

Materials Databases Infrastructure Constructed by First Principles Calculations: A Review

DOE PAGES

Lin, Lianshan

2015-10-13

The First Principles calculations, especially the calculation based on High-Throughput Density Functional Theory, have been widely accepted as the major tools in atom scale materials design. The emerging super computers, along with the powerful First Principles calculations, have accumulated hundreds of thousands of crystal and compound records. The exponential growing of computational materials information urges the development of the materials databases, which not only provide unlimited storage for the daily increasing data, but still keep the efficiency in data storage, management, query, presentation and manipulation. This review covers the most cutting edge materials databases in materials design, and their hotmore » applications such as in fuel cells. By comparing the advantages and drawbacks of these high-throughput First Principles materials databases, the optimized computational framework can be identified to fit the needs of fuel cell applications. The further development of high-throughput DFT materials database, which in essence accelerates the materials innovation, is discussed in the summary as well.« less

Kinematical and mechanical aspects of wafer slicing

NASA Technical Reports Server (NTRS)

Werner, P. G.

1982-01-01

Some recently achieved results concerning the technological fundamentals of slurry sawing are presented. The specific material removal process and the related kinematic and geometric contact conditions between workpiece and saw blade are described. The result of a functional description of the slurry sawing process is presented, expressing the main process criteria, such as infeed per stroke, specific removal rate, specific tool wear, and vertical stroke intensity, in terms of the dominating process parameters, such as stroke length, width of workpiece, stroke frequency, specific cutting force and slurry specification.

Drilling Holes in Graphite/Epoxy

NASA Technical Reports Server (NTRS)

Minlionica, Ronald

1987-01-01

Relatively long-lived bit produces high-quality holes. Effective combination of cutting-tool design, feed, and speed determined for drilling 3/16-and-1/4-in. (0.48-and 0.65-cm) diameter holes in 0.18 in. (0.46cm) thick GM3013A or equivalent graphite/epoxy corrugated spar without backup material and without coolant. Developed to produce holes in blind areas, optimal techniques yielded holes of high quality, with minimal or acceptable delamination and/or fiber extension on drill-exit side.

High performance cutting using micro-textured tools and low pressure jet coolant

NASA Astrophysics Data System (ADS)

Obikawa, Toshiyuki; Nakatsukasa, Ryuta; Hayashi, Mamoru; Ohno, Tatsumi

2018-05-01

Tool inserts with different kinds of microtexture on the flank face were fabricated by laser irradiation for promoting the heat transfer from the tool face to the coolant. In addition to the micro-textured tools, jet coolant was applied to the tool tip from the side of the flank face, but under low-pressure conditions, to make Reynolds number of coolant as high as possible in the wedge shape zone between the tool flank and machined surface. First, the effect of jet coolant on the flank wear evolution was investigated using a tool without microtexture. The jet coolant showed an excellent improvement of the tool life in machining stainless steel SUS304 at higher cutting speeds. It was found that both the flow rate and velocity of jet coolant were indispensable to high performance cutting. Next, the effect of microtexture on the flank wear evolution was investigated using jet coolant. Three types of micro grooves extended tool life largely compared to the tool without microtexture. It was found that the depth of groove was one of important parameters affecting the tool life extension. As a result, the tool life was extended by more than l00 % using the microtextured tools and jet coolant compared to machining using flood coolant and a tool without microtexture.

Effect of Moisture Content of Paper Material on Laser Cutting

NASA Astrophysics Data System (ADS)

Stepanov, Alexander; Saukkonen, Esa; Piili, Heidi; Salminen, Antti

Laser technology has been used in industrial processes for several decades. The most advanced development and implementation took place in laser welding and cutting of metals in automotive and ship building industries. However, there is high potential to apply laser processing to other materials in various industrial fields. One of these potential fields could be paper industry to fulfill the demand for high quality, fast and reliable cutting technology. Difficulties in industrial application of laser cutting for paper industry are associated to lack of basic information, awareness of technology and its application possibilities. Nowadays possibilities of using laser cutting for paper materials are widened and high automation level of equipment has made this technology more interesting for manufacturing processes. Promising area of laser cutting application at paper making machines is longitudinal cutting of paper web (edge trimming). There are few locations at a paper making machine where edge trimming is usually done: wet press section, calender or rewinder. Paper web is characterized with different moisture content at different points of the paper making machine. The objective of this study was to investigate the effect of moisture content of paper material on laser cutting parameters. Effect of moisture content on cellulose fibers, laser absorption and energy needed for cutting is described as well. Laser cutting tests were carried out using CO2 laser.

Research on subsurface deformed layer in ultra-precision cutting of single crystal copper by focused ion beam etching method

NASA Astrophysics Data System (ADS)

Chen, Y.; Huang, X. J.; Kong, J. X.

2018-03-01

In this paper, the focused ion beam was used to study the subsurface deformed layer of single crystal copper caused by the nanoscale single-point diamond fly cutting, and the possibility of using nanometer ultra-precision cutting to remove the larger deformation layer caused by traditional rough cutting process was explored. The maximum cutting thickness of single-point diamond cutting was about 146 nm, and the surface of the single-crystal copper after cutting was etched and observed by using the focused ion beam method. It was found that the morphology of the near-surface layer and the intermediate layer of the copper material were larger differences: the near-surface of the material was smaller and more compact, and the intermediate material layer of the material was more coarse sparse. The results showed that the traditional precision cutting would residual significant subsurface deformed layer and the thickness was on micron level. Even more, the subsurface deformed layer was obviously removed from about 12μm to 5μm after single-point diamond fly cutting in this paper. This paper proved that the large-scale subsurface deformed layer caused by traditional cutting process could be removed by nanometer ultra-precision cutting. It was of great significance to further establish the method that control of the deformation of weak rigid components by reducing the depth of the subsurface deformed layers.

Influence of coolant on ductile mode processing of binderless nanocrystalline tungsten carbide through ultraprecision diamond turning

NASA Astrophysics Data System (ADS)

Doetz, Marius; Dambon, Olaf; Klocke, Fritz; Fähnle, Oliver

2015-08-01

Molds made of tungsten carbide are typically used for the replicative mass production of glass lenses by precision glass molding. Consequently an ultra-precision grinding process with a subsequent fresh-feed polishing operation is conventionally applied. These processes are time consuming and have a relatively low reproducibility. An alternative manufacturing technology, with a high predictability and efficiency, which additionally allows a higher geometrical flexibility, is the single point diamond turning technique (SPDT). However, the extreme hardness and the chemical properties of tungsten carbide lead to significant tool wear and therefore the impossibility of machining the work pieces in an economical way. One approach to enlarge the tool life is to affect the contact zone between tool and work piece by the use of special cutting fluids. This publication emphasizes on the most recent investigations and results in direct machining of nano-grained tungsten carbide with mono crystal diamonds under the influence of various kinds of cutting fluids. Therefore basic ruling experiments on binderless nano grained tungsten carbide were performed, where the tool performed a linear movement with a steadily increasing depth of cut. As the ductile cutting mechanism is a prerequisite for the optical manufacturing of tungsten carbide these experiments serve the purpose for establish the influence of different cutting fluid characteristics on the cutting performance of mono crystal diamonds. Eventually it is shown that by adjusting the coolant fluid it is possible to significantly shift the transition point from ductile to brittle removal to larger depths of cut eventually enabling a SPDT of binderless tungsten carbide molds.