Tool wear

About: Tool wear is a research topic. Over the lifetime, 10580 publications have been published within this topic receiving 187761 citations. The topic is also known as: wear on cutting tools.

Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates

Abstract: In this paper, a concept of delamination factor F d (i.e. the ratio of the maximum diameter D max in the damage zone to the hole diameter D ) is proposed to analyze and compare easily the delamination degree in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates. Experiments were performed to investigate the variations of cutting forces with or without onset of delamination during the drilling operations. The effects of tool geometry and drilling parameters on cutting force variations in CFRP composite materials drilling were also experimentally examined. The experimental results show that the delamination-free drilling processes may be obtained by the proper selections of tool geometry and drilling parameters. The effects of drilling parameters and tool wear on delamination factor are also presented and discussed. Cutting temperature has long been recognized as an important factor influencing the tool wear rate and tool life. An experimental investigation of flank surface temperatures is also presented in this paper. Experimental results indicated that the flank surface temperatures increase with increasing cutting speed but decreasing feed rate. Optimal cutting conditions are proposed to avoid damage from burning during the drilling processes.

Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks

Abstract: In machining of parts, surface quality is one of the most specified customer requirements. Major indication of surface quality on machined parts is surface roughness. Finish hard turning using Cubic Boron Nitride (CBN) tools allows manufacturers to simplify their processes and still achieve the desired surface roughness. There are various machining parameters have an effect on the surface roughness, but those effects have not been adequately quantified. In order for manufacturers to maximize their gains from utilizing finish hard turning, accurate predictive models for surface roughness and tool wear must be constructed. This paper utilizes neural network modeling to predict surface roughness and tool flank wear over the machining time for variety of cutting conditions in finish hard turning. Regression models are also developed in order to capture process specific parameters. A set of sparse experimental data for finish turning of hardened AISI 52100 steel obtained from literature and the experimental data obtained from performed experiments in finish turning of hardened AISI H-13 steel have been utilized. The data sets from measured surface roughness and tool flank wear were employed to train the neural network models. Trained neural network models were used in predicting surface roughness and tool flank wear for other cutting conditions. A comparison of neural network models with regression models is also carried out. Predictive neural network models are found to be capable of better predictions for surface roughness and tool flank wear within the range that they had been trained. Predictive neural network modeling is also extended to predict tool wear and surface roughness patterns seen in finish hard turning processes. Decrease in the feed rate resulted in better surface roughness but slightly faster tool wear development, and increasing cutting speed resulted in significant increase in tool wear development but resulted in better surface roughness. Increase in the workpiece hardness resulted in better surface roughness but higher tool wear. Overall, CBN inserts with honed edge geometry performed better both in terms of surface roughness and tool wear development. q 2004 Elsevier Ltd. All rights reserved.

Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods

Abstract: The state of a cutting tool is an important factor in any metal cutting process as additional costs in terms of scrapped components, machine tool breakage and unscheduled downtime result from worn tool usage. Several methods to develop monitoring devices for observing the wear levels on the cutting tool on-line while engaged in cutting have been attempted. This paper presents a review of some of the methods that have been employed in tool condition monitoring. Particular attention is paid to the manner in which sensor signals from the cutting process have been harnessed and used in the development of tool condition monitoring systems (TCMSs).

Fundamentals of machining and machine tools

Abstract: CONVENTIONS USED IN THIS BOOK Standardization Introduction to the International (SI) System of Units MACHINE TOOLS AND MACHINING OPERATIONS Introduction Generating Motions of Machine Tools Machines Using Single-Point Tools Machines Using Multipoint Tools Machines Using Abrasive Wheels Summary of Machine Tool Characteristics and Machining Equations Problems References MECHANICS OF METAL CUTTING Introduction Terms and Definitions Chip Formation The Forces Acting on the Cutting Tool and Their Measurement Specific Cutting Energy Plowing Force and the "Size Effect" The Apparent Mean Shear Strength of the Work Material Chip Thickness Friction in Metal Cutting Analytical Modeling of Machining Operations Problems References TEMPERATURES IN METAL CUTTING Heat Generation in Metal Cutting Heat Transfer in a Moving Material Temperature Distribution in Metal Cutting The Measurement of Cutting Temperatures Problems References TOOL LIFE AND TOOL MATERIALS Introduction Progressive Tool Wear Forms of Wear in Metal Cutting The Tool Material Tool Geometries The Work Material High Speed Machining Hard Machining Problems References CUTTING FLUIDS AND SURFACE ROUGHNESS Cutting Fluids The Action of Coolants The Action of Lubricants Application of Cutting Fluids Cutting Fluid Maintenance Environmental Considerations Disposal of Cutting Fluids Dry Cutting and Minimum Quantity Lubrication Surface Roughness Tool Geometries for Improved Surface Finish Burr Formation in Machining Problems References ECONOMICS OF METAL-CUTTING OPERATIONS Introduction Choice of Feed Choice of Cutting Speed Tool Life for Minimum Cost and Minimum Production Time Estimation of Factors Needed to Determine Optimum Conditions Example of a Constant-Cutting-Speed Operation Machining at Maximum Efficiency Facing Operations Operations with Interrupted Cuts Economics of Various Tool Materials and Tool Designs Machinability Data Systems Limitations of Available Machinability Data Problems References NOMENCLATURE OF CUTTING TOOLS Introduction Systems of Cutting-Tool Nomenclature International Standard Problems References CHIP CONTROL Introduction Chip Breakers Prediction of Radius of Chip Curvature Prediction of Chip Breaking Performance Tool Wear During Chip Breaking Problems References MACHINE TOOL VIBRATIONS Introduction Forced Vibrations Self-Excited Vibrations (Chatter) Determination of Frequency Response Loci Dynamic Acceptance Tests for Machine Tools Improving Machine Tool Stability Problems References GRINDING Introduction The Grinding Wheel Effect of Grinding Conditions on Wheel Behavior Determination of the Density of Active Grains Testing of Grinding Wheels Dressing and Truing of Grinding Wheels Analysis of the Grinding Process Thermal Effects in Grinding Cutting Fluids in Grinding Grinding-Wheel Wear Nonconventional Grinding Operations Problems References MANUFACTURING SYSTEMS AND AUTOMATION Introduction Types of Production Types of Facilities Layout Types of Automation Transfer Machines Automatic Machines Numerically Controlled (NC) Machine Tools Comparison of the Economics of Various Automation Systems Handling of Components in Batch Production Flexible Manufacturing Systems Problems References COMPUTER-AIDED MANUFACTURING Introduction Scope of CAD/CAM Process-Planning Tasks Computer-Aided Process Planning Processing of NC Programs Computer-Aided NC Processing Numerical Control Processing Languages NC Programming Using APT-Based Languages Graphics-Based NC Processing Systems References DESIGN FOR MACHINING Introduction Standardization Choice of Work Material Shape of Work Material Shape of Component Assembly of Components Accuracy and Surface Finish Summary of Design Guidelines Cost Estimating for Machined Components Problems References NONCONVENTIONAL MACHINING PROCESSES Introduction Range of Nonconventional Machining Processes Ultrasonic Machining Water-Jet Machining Abrasive-Jet Machining Chemical Machining Electrochemical Machining Electrolytic Grinding Electrical-Discharge Machining Wire Electrical-Discharge Machining Laser-Beam Machining Electron-Beam Machining Plasma-Arc Cutting Comparative Performance of Cutting Processes Problems References NOMENCLATURE INDEX