Case Study 17 of Industrial Engineering ONLINE Course - Main Page
Third Wave AdvantEdgeTM is a valuable tool to determine: · cutting force and temperature to investigate tool life.
An organization wanted to explore the increase in tool life in a 316 stainless steel turning operation without any sacrifice of other productivity measures.
1.Higher temperatures reduce the tool's yield strength causing reduced tool hardness and increased tool plastic deformation failure.
2.Crater wear occurs mainly by a diffusion mechanism. Higher temperature will cause a higher diffusion rate, which, in turn, results in faster tool wear.
3. Minimize the cutting forces and the stress at the tool tip to avoid tool breakage.
The Analysis Set Setup:
Model the cutting process at the following three equivalent MRR conditions:
Speed (sfm) Feed (in.)
a) 550 0.004 the original condition
b) 425 0.005
c) 300 0.007
Depth of cut : 0.050 inches
Rake angle: 20°
Tool insert material: Tungsten carbide
Workpiece material: 316 SST
Results Analysis:
Conclusion:
Changing the cutting condition from a) to c) will increase tool life by more than 100% while
maintaining the same material removal rate and thus will decrease the total cost.
Source: http://www.engineering-eye.com/AdvantEdge/case/pdf/CS40.pdf
Tool wear and tool life are intricately tied together, and can have a big impact on your bottom line. Besides the cost of replacement parts, there are costs from downtime, reduced reliability, need for additional NDE, and lost capacity that can add up to be substantial. The factors that lead to tool wear are mechanical, thermal, chemical, and abrasive. During chip formation a significant amount of heat is generated, particularly on the flank of the tool. Due to the cyclical nature of the cutting operation these thermal loads pulsate leading to thermal fatigue of the tool material.
Types of Tool Wear:
Diffusion wear – affected by chemical loading on the tool and is controlled by the metallurgical composition of the tool and coating material;
Abrasive wear – affected by the hardness of the tool material and is controlled by the carbide content of the cutting tool material;
Oxidation wear – causes gaps to occur in coated films and results in a loss of the coating at elevated temperatures;
Fatigue wear (static or dynamic) – this is a thermomechanical effect and leads to the breakdown of the edges of the cutting tool;
Adhesion wear – occurs at low machining temperatures on the chip face of the tool and leads to the formation of a built-up-edge, and the continual breakdown of the built-up edge and the tool edge itself.
Machining Tool Selection:
Machining is a widely used process for producing intricate shapes on components and artifacts and for providing precise tolerances that are required especially for the manufacture of parts at various scales. Modern machining requires the use of minimum quantities of lubricants, dry machining capability, high cutting speeds, and long tool lives. The newly developed nanostructured thin film coatings are showing promise. There is a growing need for specially developed cutting tools for machining nanocrystalline metals and alloys. G2MT has expertise in selecting the best tool inserts and mill bits for the metal/metal alloy being machined based on analysis of the tool wear, and failure mechanisms from the machining process.
G2MT Laboratories, LLC
We strictly maintain our integrity by always reporting in an ethical and honest manner. Our key focus is providing the highest level of quality and service: reports are delivered quickly, accurately, and we follow through on our projects until your issues are fully addressed. Try us today. We are the fastest-growing metallurgical service provider in the US!
https://www.g2mtlabs.com/machining-tool-wear-analysis-consulting/
Third Wave AdvantEdgeTM is a valuable tool to determine: · cutting force and temperature to investigate tool life.
An organization wanted to explore the increase in tool life in a 316 stainless steel turning operation without any sacrifice of other productivity measures.
Third Wave AdvantEdgeTM can determine tool temperatures at various cutting speeds and feeds. The combinations of cutting speed and feed that maintain MRR but can result in the lower tool temperature profile can be identified and analyzed with the software. Tool temperature is a predominant factor affecting tool wear because:
2.Crater wear occurs mainly by a diffusion mechanism. Higher temperature will cause a higher diffusion rate, which, in turn, results in faster tool wear.
Based on the current tool wear rate, the tool/chip interface temperature is estimated to be around 700°C . For a carbide tool, if the tool/chip interface temperature is reduced from 700°C to 600°C, the crater wear rate will be reduced by more than 100%, and the tool life is expected to increase by approximately 100%. Therefore, identifying a combination of cutting speed and feed that can reduce the tool/chip interface temperature to below 600°C is the analytical and experimental problem.
3. Minimize the cutting forces and the stress at the tool tip to avoid tool breakage.
The Analysis Set Setup:
Model the cutting process at the following three equivalent MRR conditions:
Speed (sfm) Feed (in.)
a) 550 0.004 the original condition
b) 425 0.005
c) 300 0.007
Depth of cut : 0.050 inches
Rake angle: 20°
Tool insert material: Tungsten carbide
Workpiece material: 316 SST
Results Analysis:
1. Temperature, crater wear and tool life. When the cutting condition is changed from a) to c), the tool/chip interface temperature is reduced from about 700°C to below 500°C The tool life is expected to increase by more than 100%.
2. Cutting force and flank wear. When the feed increased from 0.004 inches to 0.007 inches, the total cutting force increased by about 40%. However, Third Wave AdvantEdgeä analysis indicates no significant increase in the maximum value of tension or the maximum value of pressure on the rake face. It will increase the area on the tool where the maximum tension and the maximum pressure act. Therefore, tool breakage should not be greatly aggravated under the new machining parameters.
Conclusion:
Changing the cutting condition from a) to c) will increase tool life by more than 100% while
maintaining the same material removal rate and thus will decrease the total cost.
Source: http://www.engineering-eye.com/AdvantEdge/case/pdf/CS40.pdf
Machining and Tool Wear Analysis and Consulting
Tool wear and tool life are intricately tied together, and can have a big impact on your bottom line. Besides the cost of replacement parts, there are costs from downtime, reduced reliability, need for additional NDE, and lost capacity that can add up to be substantial. The factors that lead to tool wear are mechanical, thermal, chemical, and abrasive. During chip formation a significant amount of heat is generated, particularly on the flank of the tool. Due to the cyclical nature of the cutting operation these thermal loads pulsate leading to thermal fatigue of the tool material.
Types of Tool Wear:
Diffusion wear – affected by chemical loading on the tool and is controlled by the metallurgical composition of the tool and coating material;
Abrasive wear – affected by the hardness of the tool material and is controlled by the carbide content of the cutting tool material;
Oxidation wear – causes gaps to occur in coated films and results in a loss of the coating at elevated temperatures;
Fatigue wear (static or dynamic) – this is a thermomechanical effect and leads to the breakdown of the edges of the cutting tool;
Adhesion wear – occurs at low machining temperatures on the chip face of the tool and leads to the formation of a built-up-edge, and the continual breakdown of the built-up edge and the tool edge itself.
Machining Tool Selection:
Machining is a widely used process for producing intricate shapes on components and artifacts and for providing precise tolerances that are required especially for the manufacture of parts at various scales. Modern machining requires the use of minimum quantities of lubricants, dry machining capability, high cutting speeds, and long tool lives. The newly developed nanostructured thin film coatings are showing promise. There is a growing need for specially developed cutting tools for machining nanocrystalline metals and alloys. G2MT has expertise in selecting the best tool inserts and mill bits for the metal/metal alloy being machined based on analysis of the tool wear, and failure mechanisms from the machining process.
G2MT Laboratories, LLC
We strictly maintain our integrity by always reporting in an ethical and honest manner. Our key focus is providing the highest level of quality and service: reports are delivered quickly, accurately, and we follow through on our projects until your issues are fully addressed. Try us today. We are the fastest-growing metallurgical service provider in the US!
https://www.g2mtlabs.com/machining-tool-wear-analysis-consulting/
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