Effect of cutting speed on the performance of Al2O3 based ceramic tools in turning nodular cast iron

WOS: 000239911000021This paper presents the results of an experimental investigation on the effect of cutting speed in turning nodular cast iron with alumina (Al2O3) based ceramic tools. Three different alumina based ceramic cutting tools were used, namely TiN coated Al2O3 + TiCN mixed ceramic, SiC whisker reinforced Al2O3 and uncoated Al2O3 + TiCN mixed ceramic tool. Turning experiments were carried out at four different cutting speeds, which were 300, 450, 600 and 750 m/min. Depth of cut and feed rate were kept constant at 1 mm and 0.1 mm/rev, respectively, throughout the experiments. Tool performance was evaluated with respect to tool wear, surface finish produced and cutting forces generated during turning. Uncoated Al2O3 + TiCN mixed ceramic was the worst performing tool with respect to tool wear and was the best with respect to surface finish. SiC whisker reinforced Al2O3 exhibited the worst performance with respect to cutting forces. If tool wear, surface finish and cutting force results are considered together, among the three tools studied, TiN coated Al2O3 + TiCN mixed ceramic tool is the most suitable one for turning nodular cast iron, especially at high cutting speeds (V-c > 600 m/min). (C) 2005 Elsevier Ltd. All rights reserved

A comparative study on cutting tool performance in end milling of AISI D3 tool steel

WOS: 000233438700017In this work, high speed end milling of AISI D3 cold-work tool steel hardened to 35 HRC was investigated using coated carbide, coated cermet, alumina (Al2O3) based mixed ceramic and cubic boron nitride (CBN) cutting tools. Performances of the cutting tools were compared with respect to tool life and surface finish of the workpiece. The results were also discussed in terms of tool cost. The best cutting performance was obtained with CBN tool. TiCN mixed Al2O3 ceramic tool also proved to be suitable for high speed end milling of AISI D3 steel with 35 HRC. Coated carbide and coated cermet tools, on the other hand, did not exhibit good performance in high speed cutting operations. They should rather be used at low or moderate cutting speeds. (c) 2005 Elsevier B.V. All rights reserved

A numerical model to determine temperature distribution in orthogonal metal cutting

Dogu, Yahya/0000-0003-0474-2899WOS: 000234784000001In this study, a thermal analysis model is developed to determine temperature distribution in orthogonal metal cutting using finite elements method. The model calculates the temperature distribution as a function of heat generation. The heat generation was introduced in the primary deformation zone, the secondary deformation zone and along the sliding frictional zone at the tool-chip interface, as well. The location and shapes of these zones was determined based on the literature work done so far and the model results. The temperature dependency of material properties was included in the model. A series of thermal simulations have been performed, and the value and location of maximum temperature have been determined for various cutting conditions. The comparison of the simulations with earlier works gave promising trend for the presented model. The thermal aspects of metal cutting as a result of the model findings were discussed. (c) 2005 Elsevier B.V. All rights reserved