The development of a novel cutting tool that had a micro-hole pattern on their rake and flank face of cutting tool surface has found wider potential in the field of manufacturing. Micro-hole pattern ...features on a tool rake face help in controlling the tribological characteristics of the cutting tool. Micro-holes with the different number of holes orientation, diameter and depth were fabricated using the advanced application of the electrical discharge super drilling machine with the view to assist lubricant penetration and retention. A comparative study has been conducted between micro-hole patterned Polycrystalline Diamond (PCD) cutting insert and the commercially available PCD cutting insert. The effect of micro-hole pattern on the machining of Titanium alloy (Ti-6Al-4 V) is investigated with the application of the Minimum Quantity Lubrication (MQL) method in turning operation. Vibration signals were captured in feed force direction and measured using the tri-axial accelerometer. The cutting temperature, tool-wear, and chip-morphology were measured with an infrared thermometer and Scanning Electron Microscope (SEM). It was found that micro-hole textured inserts reduced the friction on the rake face resulting in the decrease of vibration up to 30–50%. The cutting temperature, tool wear and surface roughness were reduced to 30%, 50% and 40%, respectively. The conical and helical chips were produced in micro pool lubrication system. The friction coefficient can be minimized at the tool-chip interface by using liquid lubrication method. There is no unfavourable effect on the performance of cutting tools having holes on the cutting tool surface. All these parameters led to the improvement in the tool life.
A novel cutting tool development with the micro-hole textures on the flank and rake face of the cutting inserts helps in the reduction of tribological properties. The machining of Ti–6Al–4V alloy ...leads to some challenges during machining namely higher cutting temperature, and rapid tool wear. In this research, a comparison study has been performed with the new cutting tool inserts with surface modification such as Polycrystalline Cubic Boron Nitride (PCBN) and Polycrystalline Diamond (PCD) inserts for high-speed machining of Ti–6Al–4V alloy. The influence of the micro-hole textured insert on the machining of the Ti–6Al–4V alloy was investigated with the Minimum Quantity Lubrication (MQL) method. Compared to modified PCBN inserts, modified PCD inserts showed better results in all the performance characteristics.
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•Comparison of PCD and PCBN cutting inserts were selected for machining of Ti-6Al-4V.•The PCD and PCBN inserts were modified with micro-hole surface textures on rake and flank face.•The MQL system is used as a cooling technique to reduce the cutting temperature at the machining zone.•The Modified PCD insert is proved to be the best cutting tool material for machining of Ti-6Al-4V alloy.
The present work deals with the investigation on machining of difficult-to-machine material titanium alloy (Ti-6Al-4V) using poly crystalline diamond (PCD) tool under different coolant strategies, ...namely dry, flooded and MQL. Taguchi technique has been employed and the optimization results indicated that MQL lubricating mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.25 mm depth of cut is necessary to minimize surface roughness and dry mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.75 mm depth of cut is necessary to maximize surface hardness. The results indicate the substantial benefit of the minimum quantity of lubrication (MQL) and justify PCD inserts to be the most functionally satisfactory commercially available cutting tool material for machining titanium alloys for better surface finish and hardness.
In this research, the main aim is to reduce the unfavorable effects that occurred during machining of the Ti–6Al–4V alloy by perforating the rake face and the flank face of the cutting insert. The ...main novelty in this research is that machining of Ti–6Al–4V alloy with the micro-hole textured insert helps in the improvement of tribological properties and also reduces cutting temperature at chip–tool interface with proper lubricating effect. To validate the micro-hole textured tools, it is compared with conventionally available insert. The deformation of Ti–6Al–4V alloy with modified cutting inserts was simulated, considering tool as rigid body and workpiece as elasto-plastic material. DEFORM 3D software was used for the simulation of the machining process with the updated Lagrangian formulation. To predict the cutting temperature and chip morphology, the thermo-mechanical analysis was applied using Johnson–Cook material model for the machining process. The turning of the Ti–6Al–4V alloy was carried out with the modified polycrystalline diamond (PCD) cutting inserts (Design 1 and Design 2) and commercially available PCD insert (normal insert). Coconut oil was used as a micro-pool lubricant during the machining process under minimum quantity lubrication environment. In the present work, the turning performance characteristics such as cutting temperature, cutting vibration, tool wear, chip morphology and surface integrity were measured during machining of the Ti–6Al–4V alloy. The experimental results of cutting temperature and chip morphology were validated with the simulation results with better accuracy. The machining results of Design 2 cutting insert showed maximum reduction of 30%, 38%, 45% and 35% in cutting temperature, cutting vibration, tool wear and surface roughness, respectively, when compared with machining under normal insert and Design 1 cutting insert. It is also evident from the results that machining with Design 2 cutting insert significantly improved the process performance of the product quality at higher feed rates.
Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can ...cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).
Titanium alloys are utilized in many engineering fields such as chemical, industrial, marine, and aerospace due to their unique properties. Machining of these materials causes severe problems. At ...high temperatures, they become chemically active and tend to react with tool materials. In the present study, fuzzy logic (a tool in artificial intelligence) is used for the prediction of cutting parameters in turning titanium alloy (Ti-6Al-4V). The parameters considered in this study are cutting speed, feed, and the depth of cut. Fuzzy rule-based modeling is employed for prediction of tool flank wear, surface roughness, and specific cutting pressure in machining of titanium alloy. These models can be effectively used to predict the tool flank wear, surface roughness, and specific cutting pressure in machining of titanium alloys. Analysis of the influences of the individual important machining parameters on the responses have been carried out and presented in this study.
The research reported herein is to study the comparison between a response surface methodology (RSM) and artificial neural network (ANN) in the modelling and prediction of tool wear during face ...milling of hybrid composites. Aiming to achieve this goal, several milling experiments were performed with polycrystalline diamond (PCD) inserts at different machining parameters namely feed rate, cutting speed, depth of cut and weight fraction of alumina (Al
2
O
3
). The experiment was carried out using 6061 aluminium alloy reinforced with alumina of size 65 ßm and graphite of size 60 ßm particles which are prepared using stir casting method. Mathematical model is created using central composite face centred second-order RSM and the adequacy of the model was verified using analysis of variance. With regard to the machining test, it was observed that feed rate is the dominant parameter that affects tool wear of PCD inserts. The comparison results show that models provide accurate prediction of tool wear in which ANN perform better than RSM. The data predicted from ANN is very nearer to experimental results compared to RSM, therefore we can use this ANN model to determine the tool wear for various composites and also for various machining parameters.
Based on the correlation and spectral analyses of experimental results, we have established the influence of machining conditions on the cutting force in turning silumins using tools equipped with ...round polycrystalline diamond inserts. The paper gives some practical recommendations of how to choose appropriate machining conditions.
Grinding is the most suitable process for manufacturing good quality diamond tools. In this paper, diamond wheels have been studied. From the grinding of polycrystalline diamond (PCD) insets, the ...effects of certain factors such as the bonding material, the grit size and structure of a diamond wheel have been investigated. It is concluded that vitrified bond diamond wheels are the most suitable for grinding PCDs and the recommended grit size is mesh number 1000, which can get a good surface quality within an appropriate time. The wheel structure is another important factor. Rougher wheels (mesh #800, #1000) with the softer grade scale P yield a higher material removal rate (MRR) than scale Q. However, a finer wheel (mesh #1200) needs a tougher structure to promote its grinding ability and to have a higher MRR.
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