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Investigation of the effects of machining parameters on cutting conditions during orthogonal turning of austenite stainless steel

Kónya Gábor, Takács János, Miskolczi István, Kovács Zsolt F.

Production Engineering Archives

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2024

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Vol. 30, Iss. 1

86--93

EN

The 1.4306 austenite stainless steel has been prominently utilized as a material in the automotive and aerospace industry. Considerable interest has been garnered in the machinability of stainless steel owing to its high strength and poor thermal conductivity. The aim of this study is to ascertain the influential cutting parameters, specifically the cutting speed and feed rate, on cut-ting forces, cutting temperature, and chip evaluation. Thus, austenite stainless steel was subjected to free-cutting using a carbide recessing tool under dry conditions. The principle of measuring cutting temperature, a complex procedure due to varying thermal homogeneity, was elucidated. For the turning experiments in question, the standard Taguchi orthogonal array L9 (32 ), featuring two factors and three levels, was employed. The experimental results were analyzed using MiniTab 17 software. The findings reveal a substantial effect of feed rate on cutting force, cutting temperature, and chip evaluation. The highest cutting force and cutting temperature were observed at a feed rate of 0.15 mm/rev. Conversely, the cutting force was minimized at a cutting speed of 100 m/min, indicating potential for increasing the cutting speed. The augmentation of feed rate led to chip compression and discoloration, attributed to elevated cutting force and a larger chip cross-section that efficiently dissipates heat from the cutting zone

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Investigation of the effects of machining parameters on cutting conditions during orthogonal turning of austenite stainless steel

Kónya Gábor, Takács János, Miskolczi István, Kovács Zsolt F.

Production Engineering Archives

|

2024

|

Vol. 30, Iss. 2

251--258

EN

The 1.4306 austenite stainless steel has been prominently utilized as a material in the automotive and aerospace industry. Considerable interest has been garnered in the machinability of stainless steel owing to its high strength and poor thermal conductivity. The aim of this study is to ascertain the influential cutting parameters, specifically the cutting speed and feed rate, on cutting forces, cutting temperature, and chip evaluation. Thus, austenite stainless steel was subjected to free-cutting using a carbide recessing tool under dry conditions. The principle of measuring cutting temperature, a complex procedure due to varying thermal homogeneity, was elucidated. For the turning experiments in ques-tion, the standard Taguchi orthogonal array L9 (32), featuring two factors and three levels, was employed. The experimental results were analyzed using MiniTab 17 software. The findings reveal a substantial effect of feed rate on cutting force, cutting temperature, and chip evaluation. The highest cutting force and cutting temperature were observed at a feed rate of 0.15 mm/rev. Conversely, the cutting force was minimized at a cutting speed of 100 m/min, indicating potential for increasing the cutting speed. The augmentation of feed rate led to chip compression and discoloration, attributed to elevated cutting force and a larger chip cross-section that efficiently dissipates heat from the cutting zone.

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Wear and surface characteristics on tool performance with CVD coating of Al2O3/TiCN inserts during machining of Inconel 718 alloys

Agari Shailesh Rao

Archive of Mechanical Engineering

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2022

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LXIX, nr 1

59--75

EN

The Inconel 718 alloys, which are primarily temperature resistant, are widely used in aviation, aerospace and nuclear industries. The study on dry cutting processes for this alloy becomes difficult due to its high hardness and low thermal conductivity, wherein, most of the heat transfers due to friction are accumulated over the tool surface. Further, several challenges like increased cutting force, developing high temperature and rapid tool wear are observed during its machining process. To overcome these, the coated tool inserts are used for machining the superalloys. In the present work, the cemented carbide tool is coated with chemical vapor deposition multi-layering Al 2O 3/TiCN under the dry cutting environment. The machining processes are carried out with varying cutting speeds: 65, 81, 95, and 106 m/min, feed rate 0.1 mm/rev, and depth of cut 0.2 mm. The variation in the cutting speeds can attain high temperatures, which may activate built-up-edge development which leads to extensive tool wear. In this context, the detailed chip morphology and its detailed analysis are carried out initially to understand the machining performance. Simultaneously, the surface roughness of the machined surface is studied for a clear understanding of the machining process. The potential tool wear mechanism in terms of abrasion, adhesion, tool chip off, delaminating of coating, flank wear, and crater wear is extensively identified during the processes. From the results, it is observed that the machining process at 81 m/min corresponds to a better machining process in terms of lesser cutting force, lower cutting temperature, better surface finish, and reduced tool wear than the other machining processes.

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Study of chip ignition and chip morphology after milling of magnesium alloys

Zagórski I., Kuczmaszewski J.

Advances in Science and Technology. Research Journal

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2016

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Vol. 10, nr 32

101--108

EN

The paper analyses the impact of specified technological parameters of milling (vc , fz, ap ) on time to ignition. Stages leading to chip ignition were analysed. Metallographic images of magnesium chip were presented. No significant difference was observed in time to ignition in different chip fractions. Moreover, the surface of chips was free of products of ignition and signs of strong oxidation.

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Effect of the cutting speed on the chip morphology and the cutting forces

Daymi A., Boujelbene M., Ben Salem S., Hadj Sassi B., Torbaty S.

Archives of Computational Materials Science and Surface Engineering

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2009

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Vol. 1, nr 2

77-83

EN

Purpose: The aim of this research is to make a first experimental analysis of the effect of the cutting speed on the chip morphology, and of the cutting forces in the orthogonal turning process of the titanium alloys Ti-6Al-4V. Design/methodology/approach: The methodology has consisted of proving a series of parameters combinations: f, feed rate, Vc, cutting speeds are explored in a range from 50 to 250 m/min, and is analyzing the different types of chips and the evolution cutting forces appeared during each one them, and determined the analytical model of plastic deformation ratio. Findings: Tests achieved have shown three main types of chips: Continuous chip at 50 m/min, Flow chip for speeds ranging around 100 m/min, and Shear localized chip starting from the transition speed of 125 m/min and above. The modification of the mechanism of chip formation is associated with the appearance of shearing instability. Chip segmentation by shear localisation is an important process which is observed within a certain range of cutting speeds. This phenomenon might be desirable in reducing the level of the cutting forces by improving chip's evacuation. Research limitations/implications: A possible future work would be the development of a general the phenomenal of the thermo mechanical of the cutting high speed machining. The behavior is of the thermo - visco - plastic studies are planed in the future. Practical implications: The relationship found between high speed machining and chip morphology and the cutting forces and work piece surface finish has an important practical implication since it allows selecting the best cutting condition combination from the points of view both the security and the economy for the established requirements in each case. Results are of great importance in for aerospace, biomedical and automotive industry. Originality/value: The paper is original since the bibliographical review has allowed testing that, although works about these themes exist, none approaches the problem like it has been made in work.