Prediction of tool failure rate in turning hardened steels

This paper presents a stochastic model for predicting the tool failure rate in turning hardened steel with ceramic tools. This model is based on the assumption that gradual wear, chemical wear, and premature failure (i.e. chipping and breakage) are the main causes of ending the tool life. A statistical distribution is assumed for each cause of tool failure. General equations for representing tool-life distribution, reliability function, and failure rate are then derived. The assumed distributions are then verified experimentally. From the experimental results, the coefficients of these equations are determined. Further, the rate of failure is used as a characteristic signature for qualitative performance evaluation. The results obtained show that the predicted rate of ceramic tool failure is 20% (in the first few seconds of machining) and it increases with an increase in cutting speeds. These results indicate that there will always be a risk that the tool will fail at a very early stage of cutting. Such a possibility should not be overlooked when developing proper tool replacement strategies. Finally, the results also give the tool manufacturers information which can be used to modify the quality control procedures in order to broaden the use of ceramic tools.Nomenclature c constant - ch chamfer width of the tool, mm - d depth of cut, mm - h _i hardness value at theith location on the workpiece during machining - h mean ofh ₁,h ₂,h ₃, ...,h _nn - n hardness mean location - m Meyer exponent determined experimentally to define the nonlinear relation between the cutting force and the ratioh _i/h - f feedrate, mm rev^–1 - f(t) probability density function of tool failure - f ₁(t) probability density function of tool failure due to breakage caused by tool quality - f ₂(t) probability density function of tool failure due to breakage caused by workpiece condition - f ₃(t) probability density function of tool failure due to tool chipping caused by chemical wear - f ₄(t) probability density function of tool failure due to flank wear - f ₅(t) probability density function of tool failure due to crater wear - O() error - t cutting time, min - x ₁,x ₂,...,x _n independent variables - A _i instantaneous area of contact between the tool and the workpiece - C ₁ chip load, which can be determined as a function of the cutting conditions and tool geometry - K _I crater wear index - K _T maximum depth of crater wear on tool face, mm - K _M crater centre distance, mm - N number of failures - P(t) probability function of tool failure - P _j(t) corresponding probability of failure, such that 1j5 - R tool nose radius, mm - R(t) reliability function - R _j(t) corresponding reliability function, such that 1j5 - T _V estimate of tool life for a set value of average flank wear (V _B ^* ) - T _K estimate of tool life for a set value of maximum depth of crater wear (K _T ^* ) - V cutting speed, m/min - V _B average tool wear, mm - Z(t) instantaneous failure rate or hazard function - ₃ shape parameter in the Weibull probability density function - rake angle - ₃ scale parameter in the Weibull probability density function, min - failure rate of the cutting tool - mean of a logarithmic normal distribution function - standard deviation of a logarithmic normal distribution function - tool wear function - time corresponding to the occurrence of tool failure - (.) standard logarithmic normal distribution function     

Surface roughness analysis of hardened steel after high-speed milling

The work refers to analysis of various factors affecting surface roughness after end milling of hardened steel in high-speed milling (HSM) conditions. Investigations of milling parameters (cutting speed v(c) , axial depth of cut a(p) ) and the process dynamics that influence machined surface roughness were presented, and a surface roughness model, including cutter displacements, was elaborated. The work also involved analysis of surface profile charts from the point of view of vibrations and cutting force components. The research showed that theoretic surface roughness resulting from the kinematic-geometric projection of cutting edge in the workpiece is significantly different from the reality. The dominant factor in the research was not feed per tooth f(z) (according to the theoretical model) but dynamical phenomena and feed per revolution f.     

Real-time monitoring of flank wear behavior of ceramic cutting tool in turning hardened steels

Flank wear of an alumina-based ceramic cutting tool was determined in hard turning two workpieces (AISI 4340 and 52100 hardened steels) at three cutting speeds (142, 181, and 264?m/min) to devise a real-time monitoring system. Results of the six turning tests were assessed using Kruskal?CWallis test, regression models, and linear trend analysis. Multiple non-linear regression models that explained variation in flank wear as a function of time (second) had a range of $ R_{\rm{adj}}^2 $ values of 27.7% for the test 4340-142 to 95% for the test 52100-181. Linear trend models revealed that the highest flank wear rate of the ceramic cutting tool belonged to the test 52100-181. Interaction effect of the three cutting speeds and the two workpiece types was determined to account for 82.2% of variation in flank wear (P?<?0.001). The real-time monitoring system designed in this study appeared to be promising in terms of determining and quantifying flank wear behavior of the ceramic cutting tool and optimal hard turning conditions.     

Development of a programmable vibration cutting tool for diamond turning of hardened mold steels

There are two drawbacks in the performance of the resonant vibration cutting tools currently available. One is that the vibration frequency cannot be changed arbitrarily and the other is that the cutting force is low. It is impossible to turn mirror plates with many kinds of materials using these resonant vibration cutting tools because they cannot match the desirable turning speeds that correspond to the machined materials and the vibration frequency needs to be increased or decreased to obtain the desired surface roughness. Resonant vibration cutting tools do not allow the vibration frequency to be set arbitrarily. The small cutting force of these tools also causes some difficulties in diamond turning of metals other than soft metals such as aluminum and copper. In this research, we developed a vibration cutting tool that can generate two-dimensional vibration shapes without distortion by placing two piezoelectric actuators at right angles. This tool can machine the many kinds of mirror plates with different materials to the desired surface roughness. It is also possible to machine hard materials such as mold steels because the amplitudes of the vibrations do not decrease, even when large cutting forces are required. In this paper, we describe the design of the nonresonant vibration cutting tool, and show by the diamond turning of oxygen-free copper and aluminum that our nonresonant vibration cutting tool can machine desired shapes. Finally, it is verified by actual machining experiments that the proposed vibration cutting tool can machine hardened mold steels such as STAVAX with HRC 54.     

Surface quality investigation of turbine blade steels for turning process

The quality of surface or surface finish is the widely used index of product quality and it is also critical in functional behavior of the products like turbine blades, especially when they are in contact with other medium or the materials. This paper presents the surface quality evaluation of turbine blade steels (ST 174PH, ST 12TE and ST T1/13W) for different combination of cutting parameters viz. speed, feed and depth of cut in a CNC turning process. The response surface method (RSM) is devised in design of experiments and 20 experiments per material are conducted in surface quality evaluation and analysis. The results are analyzed using ANOVA and different graphical methods like contour plot and 3D surface graphs. The reasons for the highest surface roughness of ST 174PH material are analyzed using metallurgical perspective. The regression equations for predicting the surface roughness of the materials are formulated in terms of cutting parameters based on experimental results and are verified using confirmatory experiments.     

Thermodynamic model of high-speed turning

High-speed external turning is considered. Mathematical models are proposed for the components of the cutting force, the power consumed in cutting, and the temperature of the blank. Constraints on the cutting conditions are formulated.     

Surface quality evaluation of 0.2 % C and AISI 304 steels in turning with sustainable lubricating condition

Journal of Mechanical Science and Technology - Metal working fluid (MWF) plays a significant role in metal machining operations to obtain the desired dimensional accuracy and better surface quality...     

PCBN刀具超声振动车削45淬硬钢的研究

通过采用PCBN刀具对45淬硬钢进行普通车削和超声振动车削的正交试验,研究切削用量对工件表面质量和切削温度的影响.通过两种车削方式的对比研究发现,在较小切削用量下,与普通车削相比,超声振动车削可以获得较好的表面质量和较低的切削温度.对超声振动车削切削参数进行优化,得到试验最佳切削参数.     

冷硬材料的硬车削技术浅析

分析了硬车削的定义、所需的条件以及硬车削技术在生产中的实际应用，指出硬车削技术具有广泛的应用前景。     

The cutting tool stresses in finish turning of hardened steel with mixed ceramic tool

Precision hard machining is an interesting topic in manufacturing die and mold, automobile parts, and scientific research. While the hard machining has benefit advantages such as short cutting cycle time, process flexibility, and low surface roughness, there are several disadvantages such as high tooling cost, need of rigid machine tool, high cutting stresses, and residual stresses. Especially, tool stresses should be understood and dealt with to achieve successful performance of finish hard turning with ceramic cutting tool. So, the influence of cutting parameters on cutting stresses during dry finish turning of hardened (52 HRC) AISI H13 hot work steel with ceramic tool is investigated in this paper. For this aim, a series finish turning tests were performed, and the cutting forces were measured in tests. After literature procedure about finite element model (FEM), FEM is established to predict cutting stresses in finish turning of hardened AISI H13 steel with Ceramic 650 grade insert. As shown, effect of the cutting parameters on cutting tool stresses in finish turning of AISI H13 steel is obtained. The suggested results are helpful for optimizing the cutting parameters and decreasing the tool failure in finish turning applications of hardened steel.     

Tool vibration in internal turning of hardened steel using cBN tool

The machining of hardened materials with hardness over 45 HRC has been an alternative to grinding since the 1970s, with the commercial availability of cubic boron nitride (cBN) and ceramic tools. However, the low toughness of these types of tool materials makes them very sensitive to damages caused by vibrations, which are critical for operations like internal turning, where the tool resembles a cantilever beam and therefore is susceptible to large deflections. This work aims to contribute to the study of tool performance in internal turning of long holes in hardened AISI 4340 steel in finishing conditions. Different machining conditions, two different tool holders (steel and carbide), and several tool overhangs were tested. The surface finish, acceleration (vibration) signals, and tool wear of cBN inserts were evaluated. The results show that vibration and the material of the tool holder may play a secondary role in the surface finish for stable turning, but the use of carbide tool holders makes the process stable for longer tool overhangs. Moreover, when the cutting becomes unstable, surface roughness is increased severely.     

Machinability investigation of Inconel 718 in high-speed turning

This article presents an approach based on wavelet correlation modelling for health state monitoring of fluid dynamic bearings in brushless DC motors. This approach involves two stages: (1) extracting of features from the motor-stator current signatures by analysing discrete wavelet transform coefficients; and (2) building of the simplest correlation model between the extracted features and the bearing wear using a multivariable regression technique. The correlation model can be used to detect and predict the bearing wear of brushless DC motors. Experiments were carried out using brushless DC motors with fluid dynamic bearings to verify the proficiency of this approach. Good agreement between the prediction result and the real motor health condition demonstrated the viability of the approach for bearing prognostic applications. The correlation equations obtained have acceptable detectability and accuracy based on a desired 95% level of confidence.     

淬硬钢高速切削加工技术研究

淬硬钢高速铣削加工具有传统加工无可比拟的优势,是淬硬钢加工的发展方向.从切削刀柄和刀具、加工工艺、数控编程等方面阐述了淬硬模具钢高速加工的技术特点.     

硬车代磨表面粗糙度试验研究

使用硬质合金刀具、陶瓷刀具和PCBN刀具对渗碳淬硬钢20CrMnTi进行干式车削试验,通过测量不同切削条件下的表面粗糙度值,得出切削速度、进给量对表面粗糙度的影响规律,验证了以车代磨的干式切削渗碳淬硬钢20CrMnTi的可行性.     

On the wear resistance of high-speed steels

The wear resistance of cast and strained high-speed steels are evaluated and compared, and the regularities of variations in their structure and properties depending on the austenitizing temperature are described. The impact of modification on the wear resistance of tungsten-molybdenum high-speed steels has been studied. Data on the steels with improved wear resistance are reported     

A multivariate mean square error optimization of AISI 52100 hardened steel turning

Hardened steel turning has received special attention in recent years due to its many applications in modern industries. The characteristics that define its machinability—expressed in terms of multiple response problems—are usually represented by experimental model building strategies like response surface methodology (RSM). Such strategies, however, have a particular drawback when multiple correlated regression functions are present. The optimization of multiple process characteristics without considering the variance–covariance structure among the responses may lead to an inadequate optimum. To deal with this constraint, this paper presents a novel multiobjective optimization method; it correctly focuses the multiple correlated characteristics of the AISI 52100 hardened steel, based on the concept of multivariate mean square error. This novel approach combines principal component analysis with RSM focusing a multidimensional nominal-the-best problem. In this kind of optimization, all the characteristics (tool life, cutting time, cost, material removal rate, and surface roughness) have a specific target while maintaining a strong correlation structure. Transforming the original responses and respective targets to the plane of a multivariate principal component scores, an optimization routine is capable of finding out a compromise solution that attends all the established targets. The following AISI 52100 turning process variables were considered in this study: cutting speed, feed rate, and depth of cut. Theoretical and experimental results were convergent and confirmed in a case study.     

Wear resistance of high-speed cutting powder steels with molybdenum disulfide additives

The effect of molybdenum disulphide additives on the tribological properties of high-speed powder steels produced by hot isostatic pressing has been investigated. The firction coefficients are determined at sliding velocities from 0.5 to 2.0 m/s and under loads from 1 to 15 Mpa, and the wear resistance of the experimental steel is determined. It is shown that the molybdenum disulphide additives reduce the friction coefficient and promote the wear resistance of the steel.     

高硬度淬硬钢高速铣削过程的切削温度研究

通过设计在不同加工工艺参数条件下高速铣削高硬度(48HRC～ 68HRC)淬硬钢试验,研究了切削温度信号的特征,分析了切削温度与淬硬钢材料硬度、切削工艺参数的关系.结果 表明:随着淬硬钢材料硬度的增大,切削温度呈现递增趋势,4种淬硬钢的切削温度随材料硬度变化顺序为:PM60＞SKD11＞S136＞P20,其中,PM60...     

On high-speed turning of a third-generation gamma titanium aluminide

Gamma titanium aluminides are heat-resistant intermetallic alloys predestined to be employed in components suffering from high mechanical stresses and thermal loads. These materials are regarded as difficult to cut, so this makes process adaptation essential in order to obtain high-quality and defect-free surfaces suitable for aerospace and automotive parts. In this paper, an innovative approach for longitudinal external high-speed turning of a third-generation Ti-45Al-8Nb-0.2C-0.2B gamma titanium aluminide is presented. The experimental campaign has been executed with different process parameters, tool geometries and lubrication conditions. The results are discussed in terms of surface roughness/integrity, chip morphology, cutting forces and tool wear. Experimental evidence showed that, due to the high cutting speed, the high temperatures reached in the shear zone improve chip formation, so a crack-free surface can be obtained. Furthermore, the use of a cryogenic lubrication system has been identified in order to reduce the huge tool wear, which represents the main drawback when machining gamma titanium aluminides under the chosen process conditions.