Tool Failure in Sequential Cutting of two Different Materials

In this paper the authors show that the premature tool breakage, characteristic of interrupted cutting, can be enhanced in sequential cutting of two materials having different mechanical and chemical properties. The results of experimental investigations carried out in turning pieces consisting of medium carbon steel and aluminium alloy show that the time to failure is significatively lower than that occurring in machining only one of the two materials; moreover the morphology of the damage depends by the cutting order. Working with the sequence steel-Al alloy welding phenomena caused by strong deoxidation due to the latter material are observed; these phenomena cause the early development …

Minor Cutting Edge Wear in Finish Turning Operations

In finish turning operation, it has already shown, that for the sake of control the dimensional accuracy and the micro-geometry of the worked surface, the wear parameters employed in rough turning operations are not suitable. In the present work the study of wear in fmish turning operations, is carried out, employing a particular groove survey methodology, already proposed in a previous paper, that is based on the techniques of acquirement and processing of images. In order to verify the applicability of the proposed technique two kind of alumina-based inserts and two kind of sintered carbide inserts have been tested. The experimental tests have confirmed the validity of the technique in th…

THE INFLUENCE OF TOOL STIFFNESS OF THE LIFETIME OF THE INSERTS IN INTERRUPTED CUTTING OPERATIONS

ABSTRACT In the present paper the influence exerted by the stiffness of the tool-workpiece system under working conditions on tool life up to the fracture of carbide inserts in interrupted cutting is investigated. It is shown how, with the increase in compliance of the system, there is a corresponding increase in the average tool life of the insert which is greater the lesser the cutting speed. The results of tests carried out indicate as a possible cause the amount of damage evident in the successive phase of tool engagement with the workpiece. It was observed how, in this phase, the tool, vibrating at the same rate as the toolholder produces alternations in the cutting force. This effect …

WEAR PERFORMANCE OF CERAMIC CUTTING-TOOL MATERIALS WHEN CUTTING STEEL

Abstract Some test cycles have been carried out in continuous cutting conditions, employing cutting parameters (feed, depth of cut and cutting speed) chosen following experimental planes and suitable test fields. The wear tests have been carried out on AISI 1040 steel with cutting speeds from 5m/sec to 11m/sec. The silicon nitride, sintered carbide, cubic boron nitride and alumina reinforced with SiC whiskers inserts, have shown, at each assigned cutting parameter, poor wear resistance when cutting steel. Alumina and alumina in submicron grain, which has been toughened by ZrO2 phase transformation, and the oxide-based alumina, have been the better wear resistance. The mixed based alumina ha…

A New On-Line Roughness Control in Finish Turning Operation

A new on-line control method for the wear state of sintered carbide tools for finish turning operations is proposed.

Machining of Steel with Advanced Ceramic Cutting-Tools