Investigating the Performance of Coated Carbide Insert in Hard Steel Helical Milling
محورهای موضوعی : advanced manufacturing technologyNavid Molla Ramezani 1 , Behnam Davoodi 2 , Mojtaba Rezaee Hajideh 3
1 - School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran
2 - School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran
3 - Department of Mechanical Engineering, University of Tehran, Iran
کلید واژه: High Performance Machining, Hard Steel, Coated Carbide Tool, Helical Milling,
چکیده مقاله :
Helical milling is an alternative hole-making machining process which presents several advantages when compared to conventional drilling. In the helical milling process, the tool proceeds a helical path while rotates around its own axis. Due to its flexible kinematics, low cutting forces, tool wear, and improved borehole quality may be achieved. In this study, a new helical milling process to create holes in hardened steel with a hardness of HRC 52 was used. Carbide inserts with PVD TiN coating were applied. Input parameters including cutting speed and feed rate were considered in 4 and 2 levels, respectively. In order to increase the reliability of the results, experiments were repeated 4 times and the total of 32 tests were performed. Other cutting parameters, such as axial and radial depth of cut were constant. Machining process was performed in dry state and without any lubricant. Output characteristics were tool wear, surface roughness, cutting force, machining time and material removal rate. Tool wear, surface roughness and forces, were measured by tool maker microscopy, roughness tester and dynamometer, respectively. The results showed that increasing the cutting speed on this type of hardened steel, decreases the surface roughness, machining forces and machining time. However, increasing the cutting speed and the feed rate enhances the tool wear and material removal rate considerably. Cutting speed and Feed rate of 50 m/min and 0.05 mm/tooth, offered the best mechanical properties of the Machining.
[1] Gustavo, D. S. G., Filho, M. S., and Batalha, G. F., Hard Turning of Tempered DIN 100Cr6 Steel with Coated and no Coated CBN Inserts, Journal of Materials Processing Technology Vol. 179, No. 1, 2006, pp. 146-153.
[2] Tönshoff, H. K., Arendt, C., and Ben, A. R., Cutting of Hardened Steel, CIRP Annals-Manufacturing Technology Vol. 49, No. 2, 2000, pp. 547-566.
[3] Liu, Z. Q., Ai, X., Zhang, H., Wang, Z. T., and Wan, Y., Wear Patterns and Mechanisms of Cutting Tools in High-Speed Face Milling, Journal of Materials Processing Technology, Vol. 129, No. 1, 2002, pp. 222-226.
[4] Sahoo, Kumar, A., and Sahoo, B., Performance Studies of Multilayer Hard Surface Coatings (TiN/TiCN/Al 2 O 3/TiN) of Indexable Carbide Inserts in Hard Machining: Part-II (RSM, Grey Relational and Techno Economical Approach), Measurement, Vol. 46, No. 8, 2013, pp. 2868-2884.
[5] Yamada, Y., Aoki, T., Tanaka, Y., Kitaura, S., and Hayasaki, H., (Al, Ti) N Coated Carbide Endmills for Difficult-to-Cut Materials, in: Proceedings of the Third International Conference On Progress Cutting and Grinding, 19996, pp. 211.
[6] Çalışkan, H., Kurbanoğlu, C., Panjan, P., Čekada, M., and Kramar, D., Wear Behavior and Cutting Performance of Nanostructured Hard Coatings on Cemented Carbide Cutting Tools in Hard Milling, Tribology International, Vol. 62, 2013, pp. 215-222.
[7] Kalpakjian, S, Schmid, S. R., Manufacturing Processes for Engineering Materials–5th Edition. Agenda, Vol. 12, No. 1, 2014.
[8] Molla Ramezani, N., Rasti, A., Sadeghi, M. H., Jabbaripour, B., and Rezaei Hajideh, M., Experimental Study of Tool Wear and Surface Roughness on High Speed Helical Milling in D2 Steel. Modares Mechanical Engineering, Vol. 15, No. 20, 2016, pp.198-202.
[9] Molla Ramezani, N., Ranjbar, H., Sadeghi, M. H., and Rasti, A., Helical Milling of Cold-Work AISI D2 Steel with PVD Carbide Tool under Dry Conditions, Modares Mechanical Engineering, Vol. 15, No. 20, 2016, pp.203-206.
[10] Iyer, R., Koshy, P., and Ng, E., Helical Milling: an Enabling Technology for Hard Machining Precision Holes in AISI D2 Tool Steel, International Journal of Machine Tools and Manufacture, Vol. 47, No. 2, 2007, pp. 205-210.
[11] Hao, L., He, G., Qin, X., Wang, G., Lu, C., and Gui, L., Tool Wear and Hole Quality Investigation in Dry Helical Milling of Ti-6Al-4V Alloy, The International Journal of Advanced Manufacturing Technology, Vol. 71, No. 5-8, 2014, pp. 1511-1523.
[12] Veldhuis, S. C., Dosbaeva, G. K., and Yamamoto, K., Tribological Compatibility and Improvement of Machining Productivity and Surface Integrity, Tribology International, Vol. 42, No. 6, 2009, pp. 1004-1010.
[13] Brinksmeier, Ekkard, Fangmann, S., and Meyer, I., Orbital Drilling kinematics, Production Engineering, Vol. 2, No. 3, 2008, pp. 277-283.
[14] Rech, J., Moisan, A., Surface Integrity in Finish Hard Turning of Case-Hardened Steels, International Journal of Machine Tools and Manufacture, Vol. 43, No. 5, 2003, pp. 543-550.
[15] Masato, O., Hosokawa, A., Tanaka, R., and Ueda, T., Cutting Performance of PVD-Coated Carbide and CBN Tools in Hard Milling, International Journal of Machine Tools and Manufacture, Vol. 51, No. 2, 2011, pp. 127-132.
[16] Aslan, E., Experimental Investigation of Cutting Tool Performance in High Speed Cutting of Hardened X210 Cr12 Cold-Work Tool Steel (62 HRC), Materials & Design, Vol. 26, No. 1, 2005, pp. 21-27.
[17] Fox-Rabinovich, G. S., Veldhuis, S. C., Dosbaeva, G. K., Yamamoto, K., Kovalev, A. I., Wainstein, D. L., Gershman, I. S., Shuster, L. S., and Beake, B. D., Nanocrystalline Coating Design for Extreme Applications Based on the Concept of Complex Adaptive Behavior, Journal of Applied Physics, Vol. 103, No. 8, 2008, pp. 835-860.
[18] Imani, H., Molla Ramezani, N., Sadeghi, M. H. and Rasti, A., The Effect of Hole Making Method on Cutting Force and Surface Roughness. Modares Mechanical Engineering, Vol. 15, No. 20, 2016, pp. 285-290.
[19] Molla Ramezani, N., Rezaei Hajideh, M. and Shahmirzaloo, A., Experimental Study of the Cutting Parameters Effect on Hole Making Processes in Hardened Steel. Journal of Modern Processes in Manufacturing and Production, Vol. 6, No. 3, 2017, pp. 67-76.
[20] Molla Ramezani, N., Rezaei Hajideh, M. and Shahmirzaloo, A., 2017. Experimental Study of the Cutting Parameters Effect on Hole Making Processes in Hardened Steel. Journal of Modern Processes in Manufacturing and Production, 6(3), pp.67-76.
