Investigation of force parameters acting on a single cutting insert made of ceramics in face milling of hardened steel

In the present paper, mathematical models for force parameters affecting single cutting insert made of oxide ceramics during finish milling of hardened steels are derived taking into account wear of inserts. Experiments showed that nitride Physical Vapor Deposition (VPD) coatings on oxide ceramics substrate CC6(Al2O3-TiC) produced by Moscow State University of Technology “STANKIN” provide at least 10% decrease of cutting forces. It was realized that cutting inserts wear influences the force parameters, especially axial force Px, that makes it possible to use those parameters as diagnosis indicators

Real-Time Simulation of Force Parameters for Diagnostics of Ceramic Tool Condition During Milling of High-Hardness Steel Parts

Cutting ceramics is a high-performance tool material for high-speed machining of hard steels and alloys. Ceramic materials have high hardness and heat resistance in a wide range of temperatures, as well as chemical passivity in relation to most of the workpieces. However, the wider application of ceramic cutting tools is limited due to the low reliability - unpredictable fragile fracture of the cutting edge in different periods of operation. The study discusses mathematical simulations of force parameters in the milling of hardened steels using ceramic cutting tools. The simulation results were used to develop a system for the metalworking technological system state diagnostics. Mathematical software for calculations of the set of force parameters through computer simulations with taking into account the tool wear has been developed. The developed system allows calculating and graphically displaying a set of force parameters appearing during face milling of hardened steels in the real-time

Real-Time Simulation of Force Parameters for Diagnostics of Ceramic Tool Condition During Milling of High-Hardness Steel Parts

Cutting ceramics is a high-performance tool material for high-speed machining of hard steels and alloys. Ceramic materials have high hardness and heat resistance in a wide range of temperatures, as well as chemical passivity in relation to most of the workpieces. However, the wider application of ceramic cutting tools is limited due to the low reliability - unpredictable fragile fracture of the cutting edge in different periods of operation. The study discusses mathematical simulations of force parameters in the milling of hardened steels using ceramic cutting tools. The simulation results were used to develop a system for the metalworking technological system state diagnostics. Mathematical software for calculations of the set of force parameters through computer simulations with taking into account the tool wear has been developed. The developed system allows calculating and graphically displaying a set of force parameters appearing during face milling of hardened steels in the real-time

Study of layers’ structure defects of 3D objects obtained by selective laser melting

Current work was aimed to study of layers’ structure defects of 3D-objects obtained by selective laser melting with the modulated laser beam mode. Traditionally Gaussian laser beam mode uses for the processing in selective laser melting. On the developed experimental setup, the alternative laser beam modes as Flat-top and Inverse Gaussian were obtained. With the carried out experiments 3D-objects contained 10 layers were produced from CoCrMo powder with the diameter of granules less than 20 μm. The layers’ structure defects as penetration of the substrate material into the body of produced objects were studied by optical and scanning electronic microscopy

Modeling of 3D technological fields and research of principal perspectives and limits in productivity improvement of selective laser melting

Nowadays the technological perspectives of selective laser melting are limited by available equipment on the market. Most of the manufactures produce SLM-machine with the maximum power of laser system 200 W, this makes processing very slow and it significantly reduces the field of potential applications for the technology. Meanwhile the limits of laser power are linked to a problem of its effective use. In the current work, the future perspectives of technology are investigated by modeling of 3D technological fields

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling)