Suitability of natural rocks as materials for cutting tools

This study presents an investigation of the usability and suitability of natural rocks as cutting tool materials. Therefore, indexable inserts are manufactured from eight different rocks and two mono minerals in this study and are used for turning of an aluminium alloy. Besides that, a characterization of the rock properties is performed. The wear of the rock tools and the surface roughness of the workpiece generated by the tools are used to evaluate their operational behaviour. Subsequently, the rock properties and the corresponding operational behaviour are used to assess the suitability of the rocks as cutting tool material. The results show that rock inserts can be used as cutting material for the turning of an aluminium alloy showing a width of wear marks between 83 and 1665 µm at the flank face after a cutting length of 500 m depending on the rock used. Furthermore, it is shown that rock tools are able to achieve surface roughness values which are comparable to those obtainable by using a conventional cemented carbide insert. The study shows that natural rocks can generally be used as alternative cutting material for the turning of aluminium. In addition a possible way for a systematic investigation and assessment of the suitability of natural rocks as cutting tool materials is presented, the relevance of the rock properties for the operational behaviour of the rock inserts is described and relevant future research topics concerning the use of rocks as cutting tool material are identified

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

AbstractAmong the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiCp/Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiCp/Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiCp/Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiCp/Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiCp/Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications

Three-Dimensional Finite Element Analysis of Conventional and Ultrasonic Vibration Assisted Micro-Drilling on PCB

Recent advancement in society’s demands has forced industries to produce more and more precise micro parts. With an advancement in engineering sciences, current manufacturers in various fields such as aerospace, medical, electronics, automobile, biotechnology, etc. have achieved the potential to fabricate miniaturized products, but with numerous technical challenges. Dimensional accuracy and surface integrity of the machined components are the key challenges and at the same time, cost minimization is strongly desired. To meet these challenges and demands, improvements in machining regarding new procedures, tooling, tool materials and modern machine tools are highly essential. Micromachining has shown potential to achieve the fast-growing needs of the present micro manufacturing sector. Additionally, new machining techniques like ultrasonic machining, laser drilling, etc. have been developed as an alternative source to reduce obstructions caused during macro/micro machining. The present research aims to perform three-dimensional (3D) finite element dynamic analysis for micro-drilling of multi-layer printed circuit boards (PCBs). Both conventional and ultrasonic vibration assisted micro-drilling (UVAMD) FE simulations have been compared to predict and evaluate the effect of process parameters on the output responses like stress generation and reaction forces and burr formation on the workpiece surfaces. The Lagrangian based approach is followed for the FE simulation including the mass and inertial properties of the proposed FE model. The predicted FE results are compared with the past experimental work for thrust force evaluation and burr formation on workpiece surfaces. The present work is supported with modal and harmonic analysis of stepped and conical horns along with micro drill bit. Here, horns made up of Aluminum 6061-T6, Titanium and Mild steel are chosen with micro drill bit of 0.3 mm diameter with varying tool materials (Tungsten carbide and High speed steel). The effects of natural frequencies with different mode shapes within the range of 15-30 kHz are shown. The frequency responses of micro drill with displacement conditions have been presented for longitudinal modes. The present simulation results will be helpful to conduct proper experimentation in order to achieve efficient machining and surface finish. The results enumerate that the drilling parameters have a strong influence on thrust forces and stresses occurring in micro-drilling. Ultrasonic assisted micro-drilling has a good potential in reduction of forces generated by vii selecting proper machining parameters. The FE simulation of UVA micro machining can further be enhanced and extended to various materials like plastics, sheet metal, other PCBs, etc. to predict the performance with varying machining and geometrical parameters

Investigation of cutting mechanics in single point diamond turning of silicon

As a kind of brittle material, silicon will undergo brittle fracture at atmospheric pressure in conventional scale machining. Studies in the last two decades on hard and brittle materials including silicon, germanium, silicon nitride and silicon carbide have demonstrated ductile regime machining using single point diamond turning (SPDT) process. The mirror-like surface finish can be achieved in SPDT provided appropriate tool geometry and cutting parameters including feed rate, depth of cut and cutting speed are adopted.The research work in this thesis is based on combined experimental and numerical smoothed particle hydrodynamics (SPH) studies to provide an inclusive understanding of SPDT of silicon. A global perspective of tool and workpiece condition using experimental studies along with localized chip formation and stress distribution analysis using distinctive SPH approach offer a comprehensive insight of cutting mechanics of silicon and diamond tool wear. In SPH modelling of SPDT of silicon, the distribution of von Mises and hydrostatic stress at incipient and steady-state was found to provide the conditions pertinent to material failure, phase transformation, and ductile mode machining. The pressure-sensitive Drucker Prager (DP) material constitutive model was adopted to predict the machining response behaviour of silicon during SPDT. Inverse parametric analysis based on indentation test was carried out to determine the unknown DP parameters of silicon by analysing the loading-unloading curve for different DP parameters. A very first experimental study was conducted to determine Johnson-Cook (J-C) model constants for silicon. High strain rate compression tests using split Hopkinson pressure bar (SHPB) test as well as quasi-static tests using Instron fatigue testing machine were conducted to determine J-C model constants.The capability of diamond tools to maintain expedient conditions for high-pressure phase transformation (HPPT) as a function of rake angle and tool wear were investigated experimentally as well as using SPH approach. The proportional relationship of cutting forces magnitude and tool wear was found to differ owing to wear contour with different rake angles that influence the distribution of stresses and uniform hydrostatic pressure under the tool cutting edge. A new quantitative evaluation parameter for the tool wear resistance performance based on the cutting distance was also proposed. It was also found that the machinability of silicon could be improved by adopting novel surface defect machining (SDM) method.The ductile to brittle transition (DBT) with the progressive tool wear was found to initiate with the formation of lateral cracks at low tool wear volume which transform into brittle pitting damage at higher tool edge degradation. A significant variation in resistance to shear deformation as well as position shift of the maximum stress values was observed with the progressive tool wear. The magnitude and distribution of hydrostatic stress were also found to change significantly along the cutting edge of the new and worn diamond tools.As a kind of brittle material, silicon will undergo brittle fracture at atmospheric pressure in conventional scale machining. Studies in the last two decades on hard and brittle materials including silicon, germanium, silicon nitride and silicon carbide have demonstrated ductile regime machining using single point diamond turning (SPDT) process. The mirror-like surface finish can be achieved in SPDT provided appropriate tool geometry and cutting parameters including feed rate, depth of cut and cutting speed are adopted.The research work in this thesis is based on combined experimental and numerical smoothed particle hydrodynamics (SPH) studies to provide an inclusive understanding of SPDT of silicon. A global perspective of tool and workpiece condition using experimental studies along with localized chip formation and stress distribution analysis using distinctive SPH approach offer a comprehensive insight of cutting mechanics of silicon and diamond tool wear. In SPH modelling of SPDT of silicon, the distribution of von Mises and hydrostatic stress at incipient and steady-state was found to provide the conditions pertinent to material failure, phase transformation, and ductile mode machining. The pressure-sensitive Drucker Prager (DP) material constitutive model was adopted to predict the machining response behaviour of silicon during SPDT. Inverse parametric analysis based on indentation test was carried out to determine the unknown DP parameters of silicon by analysing the loading-unloading curve for different DP parameters. A very first experimental study was conducted to determine Johnson-Cook (J-C) model constants for silicon. High strain rate compression tests using split Hopkinson pressure bar (SHPB) test as well as quasi-static tests using Instron fatigue testing machine were conducted to determine J-C model constants.The capability of diamond tools to maintain expedient conditions for high-pressure phase transformation (HPPT) as a function of rake angle and tool wear were investigated experimentally as well as using SPH approach. The proportional relationship of cutting forces magnitude and tool wear was found to differ owing to wear contour with different rake angles that influence the distribution of stresses and uniform hydrostatic pressure under the tool cutting edge. A new quantitative evaluation parameter for the tool wear resistance performance based on the cutting distance was also proposed. It was also found that the machinability of silicon could be improved by adopting novel surface defect machining (SDM) method.The ductile to brittle transition (DBT) with the progressive tool wear was found to initiate with the formation of lateral cracks at low tool wear volume which transform into brittle pitting damage at higher tool edge degradation. A significant variation in resistance to shear deformation as well as position shift of the maximum stress values was observed with the progressive tool wear. The magnitude and distribution of hydrostatic stress were also found to change significantly along the cutting edge of the new and worn diamond tools

Effect of electromagnetic field in machining process

Master'sMASTER OF ENGINEERIN

Microstructural investigation of CVD TiAlN, TiN and WN coatings

High speed machining of workpiece materials puts extreme thermal and pressure loads onto the cutting tool inserts, which thus must possess both high hardness and good toughness. Nowadays, most cutting tools are made of cemented carbide substrates that are coated with wear-resistant coatings. Chemical vapour deposition (CVD) is a widely used industrial method for producing the wear-resistant coatings, and has advantages like conformal coverage of irregular shapes and high purity of the deposited materials. However, CVD is a complex process and the coating growth is therefore not fully understood.This thesis focuses on examining topics of relevance to increase the understanding of hard nitride coatings synthesized by CVD. The main research methods are analytical transmission and scanning electron microscopy (TEM and SEM), with complementary X-ray diffraction (XRD), atom probe tomography (APT) and simulations. Three types of CVD coatings were studied in this work: TiAlN coatings, TiN coatings and WN coatings.The work on TiAlN coatings: (i) First, the growth facets and texture were revealed. (ii) Second, an effect of precursor gas flow on the growth of the coating was studied, including the correlation between the formation of a nanolamella structure and the rotating precursor gas supply, and a microstructural inhomogeneity relevant to the varying gas environment. (iii) In addition, the full chemical composition of the TiAlN coating was studied via APT and electron microscopy. (iv) Finally, an intra-grain misorientation that forms in TiAlN during the CVD growth, and the formation of relevant dislocations, was studied. The work on TiN coatings: (i) The microstructure of the CVD TiN coatings deposited on a CoCrFeNi multi-principal elemental alloy (MPEA) substrate was studied, and (ii) the etching effect of the corrosive gas environment on the MPEA substrate was evaluated. The work on WN coatings: The microstructure and grain morphology of WN deposited on a (0001) sapphire substrate, especially the influence of deposition temperature on the microstructures, were studied.In conclusion, the results presented in this thesis provide insights into the detailed microstructures of TiAlN, TiN and WN coatings, which will increase the understanding of the growth mechanisms for these CVD coatings

Machinability of Ti6Al4V alloy produced by electron beam melting under different lubricating conditions

In the last decade, the growing diffusion of metal additive manufacturing technologies is revolutionising the manufacturing processes of the most advanced industrial fields. Nowadays, more and more companies operating in the aeronautic and in the biomedical field are employing the additive manufacturing technology of Electron Beam Melting (EBM) to produce prosthesis and aero engine parts made of the titanium alloy Ti6Al4V, traditionally produced by hot forging and machining. Thanks to this technology, it is possible to realise a complex shape component with tailored mechanical and geometrical properties, passing from the 3D CAD model directly to the near net shape geometry without any intermediate manufacturing steps, thus cutting the production costs. However, finishing machining operations are still necessary to remove the surface porosity that is a direct and inevitable consequence of additive manufacturing technologies, and to achieve higher surface quality and geometrical accuracy. Aiming to optimize the machining operation and to avoid detrimental surface damages left on the final product, the material machinability has to be taken into account. At the moment, many efforts coming from both the academic and industrial research have been spent to enhance the poor machinability of wrought Ti6Al4V alloy due to the increasing demand from the aeronautic field; however no published works and technical data are available regarding the machinability of EBM Ti6Al4V that presents different mechanical properties. Within the biomedical field, the surgical replacements made of Ti6Al4V are traditionally machined under flood coolants, made of synthetic or vegetable oil and water emulsions. As a consequence, costly sterilizing and cleaning operations are performed to remove the toxic and pollutant chemical residuals left on the finished products at the end of the manufacturing process. Thus, there is a need to revise the traditional lubricating strategies applied in machining operations of surgical implants, proposing an innovative solution that might satisfy technological, environmental and economic issues. In this PhD thesis, an innovative cryogenic cooling line has been developed and implemented to turn EBM Ti6Al4V alloy, as a promising alternative to standard cooling methods applied in machining surgical implants. The alloy machinability has been firstly investigated trough an experimental approach, evaluating the effects of three different cooling methods namely: dry, wet and cryogenic and of different cutting parameters, on the tool wear, on the surface integrity and on the chip morphology. Subsequently, a FE numerical model has been developed to simulate the turning operation of EBM Ti6Al4V alloy, capable to predict the effects of different process conditions. Due to the beneficial effects induced by the cryogenic cooling on the surface integrity of turned Ti6AL4V EBM test pieces, the feasibility of such technology for biomedical applications has been validated by means of wear tests: the wear resistance of cryogenically machined specimens clearly increased with a strong reduction of metallic particles loss. Finally, cryogenic turning has been employed to machine real acetabular cups, in comparison with standard cooling methods applied in machining surgical implants. The beneficial effects imparted by cryogenic cooling in terms of improved material machinability, improved wear resistance and satisfying achievable geometrical accuracy, foresee a potential applicability of this technology in the biomedical field for years to come

Technologies of Coatings and Surface Hardening for Tool Industry

The innovative coating and surface hardening technologies developed in recent years allow us to obtain practically any physical–mechanical or crystal–chemical complex properties of the metalworking tool surface layer. Today, the scientific approach to improving the operational characteristics of the tool surface layers produced from traditional tools industrial materials is a highly costly and long-lasting process. Different technological techniques, such as coatings (physical and chemical methods), surface hardening and alloying (chemical-thermal treatment, implantation), a combination of the listed methods, and other solutions are used for this. This edition aims to provide a review of the current state of the research and developments in the field of coatings and surface hardening technologies for cutting and die tools that can ensure a substantial increase of the work resource and reliability of the tool, an increase in productivity of machining, accuracy, and quality of the machined products, reduction in the material capacity of the production, and other important manufacturing factors. In doing so, the main emphasis should be on the results of the engineering works that have had a prosperous approbation in a laboratory or real manufacturing conditions