Search results for "Tool wear"

Advanced Machining Processes

2017

This chapter provides comprehensive knowledge regarding both well-established achievements in manufacturing and new trends in improving machining processes, taking into account physical, design and technological aspects. The background of machining advancements is outlined, including all components of the machining system and typical machining operations such as turning, milling and drilling and different construction materials. In particular, this short survey covers such machining techniques as high-speed machining/cutting (HSM/HSC), hard part machining, dry and near-dry machining (MQL), high-performance machining (HPM), multitasking/complete machining, and assisted and hybrid machining. …

On the use of SLS tools in sheet metal stamping

2003

Abstract A few rapid tooling technologies have been recently proposed and among them Selective Laser Sintering is probably one of the most relevant and promising. In the paper, the authors report some results of a wide experimental research on the application of SLS tools in sheet metal forming. A wear test was earned out to investigate the progressive degradation of laser-sintered materials in comparison with traditional cold-work steels. In particular SLS tools were utilized in a sheet metal stamping process of S-shaped parts: their performances (in terms of tool wear and dimensional quality of the stamped part) were compared with the ones of traditional tools.

ALE Simulation of Orthogonal Cutting: a New Approach to Model Heat Transfer Phenomena at the Tool-Chip Interface

2007

This paper presents a new procedure to evaluate the global heat transfer coefficient in orthogonal cutting. The knowledge of the actual heat transfer conditions is a fundamental issue as far as the life, tool wear and tool substitution interval are regarded. More in detail, an Arbitrary Lagrangian-Eulerian approach was utilised to model orthogonal cutting process and the numerical simulations were validated by making experimental tests for identifying cutting forces and internal tool temperatures. A mild steel was cut utilising both an uncoated (WC) and a coated (TiN) tool. On the basis of both experimental and simulative data, a consistent model of the global heat transfer coefficient as f…

3D finite element analysis of tool wear in machining

2008

Abstract The paper is focused on the 3D numerical prediction of tool wear in metal cutting operations. In particular, an analytical model, able to take into account the diffusive wear mechanism, was implemented through a specific subroutine. Furthermore, an advanced approach to model heat transfer phenomena at the tool–chip interface was included in the numerical simulation. The adopted simulation strategy gave the possibility to properly evaluate the tool wear. The 3D FEM results were compared with some experimental data obtained turning AISI 1045 steel using uncoated WC tool; a good agreement was found out.

Sensor-Assisted Machining

2008

This chapter provides comprehensive knowledge regarding the application of various sensors and monitoring techniques to machining processes, cutting tools and machine tools. A number of monitoring methods used in manufacturing and relevant sensors are characterized. In particular, three most frequently used sensors, i.e., force, acceleration and acoustic emission, are presented and their characteristics and advantages are highlighted. The architectures of multiple-sensor tool-monitoring systems for detection of tool wear and breakage and collision for machine tools, including details of sensor fusion, signal processing and decision-making, are presented. Moreover, the concepts of sensor-bas…

Prediction of Tool Wear in Machining

2007

On the effectiveness of Finite Element simulation of orthogonal cutting with particular reference to temperature prediction

2007

Abstract Finite Element simulation of orthogonal cutting is nowadays assuming a large relevance; in fact a very large number of papers may be found out in technical literature on this topic. In recent years, numerical simulation was performed to investigate various phenomena such as chip segmentation, force prediction and tool wear. On the other hand, some drawbacks have to be highlighted; due to the geometrical and computational complexity of the updated-Lagrangian formulation mostly used in FE codes, a cutting time of only a few milliseconds can be effectively simulated. Therefore, steady-state thermal conditions are not reached and the simulation of the thermal phenomenon may be ineffect…

Wear modelling in mild steel orthogonal cutting when using uncoated carbide tools

2007

Abstract Wear prediction in machining has been recently studied by FEM although the use of numerical methods for such applications is still a very challenging research issue. In fact, wear phenomenon involves many aspects related to process mechanics which require a very accurate modelling. In other words, only a very punctual code set-up can help the researchers in order to obtain consistent results in FE analysis. The high relative velocity between chip and tool requires effective material models as well as friction modelling at the interface. Moreover the prediction of temperature distribution is another critical task; in the paper some different procedures are discussed. Subsequently a …

Tool Wear and Damage

2008

This chapter provides comprehensive knowledge regarding tool wear mechanisms and characterizes their physical fundamentals. Adhesion, abrasion, diffusion and oxidation are selected as predominant mechanisms controlling tool wear, depending on the mechanical and thermal conditions at the rake and flank faces. The analytical models describing the wear rate and volumetric material loss for different wear mechanisms are provided. The tool wear indicators related to crater, flank and notch wear specified in ISO 3685 are presented for both flat-faced and grooved tools. Tool life is defined and corresponding models, including the influence of cutting speed, feed and the depth of cut, are derived. …

Metal Matrix Composites - Mmc - Turning: Comparison of Tool Materials

2002

The main properties required to the modem cutting tools to be employed in production, are both high wear resistance and chemical stability. In this last years, in the machining of MMCs several kinds of coated tools have been developed; they are characterized by high hardness to resist to the relevant strength and abrasive action of the reinforce fibers or particles, arranged inside the matrix. In turning of MMC the employ of Tungsten Carbide tools coated with Polycrystalline Diamond (PCD) have shown to be very effective, whereas they are very expensive thus increasing the production costs.