Tool wear monitoring and hole surface quality during CFRP drilling

The present investigation focuses on the evaluation of tool wear and surface integrity in the context of CFRP cutting. Series of drilling experiments were performed on CFRP plates using cemented carbide solid drills with the aim to investigate correlations between tool damage, cutting forces, temperature and hole surface quality. In particular, a new methodology has been developed to measure the drilling temperature and to assess the quality of the hole surfaces where occurred uncut fibers. As the surface roughness criterion is not relevant for such work materials, a discussion on the definition of the surface topography is proposed for CFRP work material

A quick method for evaluating the thresholds of workpiece surface damage in machining

© 2019 This paper proposes a Pendulum-Based Cutting Test (PBCT) methodology which allows quick cutting tests for surface integrity evaluation along with providing cutting energies associated with particular level of workpiece surface damage, this is backed by an unified cutting energy model that links damage level of machined surface with energy partition in the cutting area. PBCT method could rapidly define the energy transferred to the workpiece that incurs particular magnitude of surface damage without using conventional machine tools and monitor the cutting process while only limited amount of materials is required. A demonstration of the proposed method is presented for Inconel718

Tool life and surface integrity in hard milling of hot work tool steels

Machinability enhancement of hot work tool steels can be achieved intrinsically through tailoring of alloying elements and steel processing route but also externally through the use of adequate tooling. The aim of the present investigation was to identify the limitations in hard milling of AISI H13 (50HRC) with respect to different strategies for microstructure control. Accordingly, tool life tests in face and cavity milling were performed using modern PVD-coated carbide inserts where subsequent investigation of tool wear mechanisms and surface integrity were carried out. A modified tool life model derived from Taylor’s approach was employed for the assessment of tool life. The results indicate that traditional improvement in machinability through additives and inclusion control appears not always adequate and the role of primary carbides distribution needs also to be considered. Surface integrity studies, namely residual stress, indicate the predominance of compressive residual stress in the machined surfaces

Tool life and surface integrity in hard milling of hot work tool steels

Machinability enhancement of hot work tool steels can be achieved intrinsically through tailoring of alloying elements and steel processing route but also externally through the use of adequate tooling. The aim of the present investigation was to identify the limitations in hard milling of AISI H13 (50HRC) with respect to different strategies for microstructure control. Accordingly, tool life tests in face and cavity milling were performed using modern PVD-coated carbide inserts where subsequent investigation of tool wear mechanisms and surface integrity were carried out. A modified tool life model derived from Taylor’s approach was employed for the assessment of tool life. The results indicate that traditional improvement in machinability through additives and inclusion control appears not always adequate and the role of primary carbides distribution needs also to be considered. Surface integrity studies, namely residual stress, indicate the predominance of compressive residual stress in the machined surfaces

Novel cutting inserts with multi-channel irrigation at the chip-tool interface: Modelling, design and experiments

© 2020 CIRP The friction at chip-tool interface can considerably affect the chip formation and consumed energy during cutting of superalloys. However, it is difficult to deliver the lubricant to the chip-tool interface to reduce the friction effect. Thus, this paper proposed a novel solution of insert design by locating macro-channels on the rake face which connect with the micro-channels for irrigating the coolant into the chip-tool interface, while considering the cooling and lubricating efficiency. A significant reduction of tool wear, cutting force and specific cutting energy has been demonstrated, while an improved chip fragmentation as well as microstructure has also been achieved

Can higher cutting speeds and temperatures improve the microstructural surface integrity of advanced Ni-base superalloys?

Future Ni-base superalloys are designed to deliver outstanding mechanical behaviour at high temperatures, which may translate in significant machining challenges. In this work, a paradigm is presented by which is proven how machining of these materials could benefit from increased cutting speeds and temperatures provided that they are able to promote shear localisation and thermal softening in the chip deformation zones, whilst retaining high-temperature strength within the machined surface. In this way, thermal control of chip formation leads to both lower cutting forces and energies, as well as enhanced surface integrity with lower levels of microstructural reconfiguration

Temperature-dependent shear localisation and microstructural evolution in machining of nickel-base superalloys

Understanding the microstructural evolution mechanisms in machining of advanced materials is essential to achieve excellent surface integrity levels within the manufacture of safety–critical components. However, as thermal and mechanical effects are coupled in conventional cutting operations, it is difficult to attribute their individual role on microstructural evolution and integrity. To investigate the temperature-dependency of microstructural evolution in cutting, a new experimental set-up has been developed to perform machining experiments under controlled temperatures. Results show that an onset in chip shear localisation with nanocrystalline grain refinement can be induced uniquely by an increase in cutting temperature under fixed cutting parameters, which microstructurally controls the transition from continuous to serrated chip formation. Increase in mechanical effects at HT leads to the formation of a continuous chip grain refinement layer, associated to a change in energy partition at the tool-workpiece interface. These small-scale behaviours are found to control the reduction in cutting forces and energy at higher temperatures, with a decrease of ∼ 25–30%. Nevertheless, despite the lower deformation energy, HT cutting induced larger amounts of microstructural deformation because of thermal softening effects, further disclosing the role of thermal effects on the interplay between shear localisation, microstructural evolution and surface integrity

A constitutive model for Ti6Al4V considering the state of stress and strain rate effects

The predictability of manufacturing process simulation is highly dependent on the accuracy of the constitutive model to describe the mechanical behavior of the work material. The model should consider the most relevant parameters affecting this behavior. In this study, a constitutive model for Ti6Al4V titanium alloy is proposed that considers both material plasticity and damage. It includes the effects of strain hardening, strain-rate and the state of stress to represent the mechanical behavior of Ti6Al4V titanium alloy in metal cutting simulation. To generate states of stress and strain rates representative of this process, mechanical tests were performed using a specific experimental setup. This included a specimen geometry designed to generate different states of stress, as well as a digital image correlation technique to obtain the strains during the mechanical tests. For the determination of the coefficients of the constitutive model, the yield stress and fracture locus obtained from these tests were used in an optimization-based procedure. To verify the accuracy of the proposed constitutive model to represent the mechanical behavior of the Ti6Al4V alloy under different states of stress, force–displacement curves obtained using this model and the Johnson-Cook model are compared with the curves obtained experimentally

Mechanical integrity of PVD TiAlN-coated PcBN: Influence of substrate bias voltage and microstructural assemblage

Polycrystalline cubic boron nitrides (PcBN) have been increasingly used together with PVD coatings, mainly for hard turning operations. Within this context, effectiveness of coated PcBN as cutting tool is usually addressed by evaluation of its machining performance. Meanwhile, studies aiming to assess and understand the correlation between microstructural features and mechanical behaviour of the coating-substrate system are rather limited. Aiming to overcome such lack of information, in this study the influence of substrate bias voltage (-35¿V as compared to -60¿V) and microstructural assemblage (as a function of cBN content and binder chemical nature) on the mechanical integrity of TiAlN-coated PcBN systems is investigated. In doing so, contact damage response and coating adhesion strength of different coated-PcBNs are evaluated by means of indentation testing using distinct loading conditions (static and sliding) and tip geometries (spherical and conical). Such testing program is complemented by detailed FESEM inspection of the involved failure micromechanisms, as well as microstructural and micromechanical characterization of the deposited films. Results indicate that resistance against crack nucleation and propagation of coated PcBN, induced by either spherical or conical indentation, is enhanced by using harder (high content of cBN particles) and tougher (metallic binder) substrates (H-PcBN). Regarding bias voltage, systems with coatings deposited using a higher value (-60¿V as compared to -35¿V) show improved adhesive strength, this being particularly true for combinations involving low cBN content and ceramic binder substrate (L-PcBN). Similar beneficial effect was found, but exclusively in coated L-PcBN systems, regarding resistance to radial cracking emergence and to material removal through cohesive-failure chipping induced in Rockwell C tests. Although these findings are linked to the higher compressive residual stresses exhibited by coatings deposited under -60¿V bias voltage, the latter does not translate in significant changes in microstructural and intrinsic mechanical properties of the TiAlN coating itself.The study was supported by the Spanish Government (Ministerio de Ciencia, Innovación y Universidades and Agencia Estatal de Investigación) and European Union (FEDER) through the projects PID2021-126614OB-100 and PID2022-137274NB-C32, as well as by an industry-university collaborative program among Element Six (UK) Ltd., Seco Tools AB and Universitat Politècnica de Catalunya. Authors acknowledge Mikael Fallqvist (Karlstad University) for support in conducting the scratch test experiments at Seco Tools.  Peer ReviewedPostprint (published version

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