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Through an experiment involving the taperness of holes bored into carbon-coated delrin, the study aims to measure the diameter of coated and coated untreated material. In the study, surface flaws that occur when drilling Delrin with drill bits that are coated with carbon and those that are not are compared. Procedures and Materials: Delrin is another name for acetal resin, a high-performance substance with many useful physical and mechanical characteristics. The dimensional stability, hardness, and rigidity of this carefully made thermoplastic are unparalleled. A highly crystalline structure is used to assess the drill bit's stability. It is possible to make drill bits with or without a Delrin covering. In terms of diameter, the drill bit measures 6 mm. A length of 10 cm is the measurement of the drill bit. The drill bit's effectiveness was evaluated according to several drilling standards. stability. Many different materials may be drilled, including metal, wood, concrete, and many more. A strong, lightweight material that may be used in every situation is called Delrin. Bore bit coated with Delrin. It was possible to monitor the depth of the hole, the drilling temperature, the material's tension and shear stress after the fact. Interdependence exists among the variables. drill bit uncoated with Delrin The coating procedure is applicable to both the coated and uncoated drill bits. The uncoated drill bit is used for drilling. many different kinds of surfaces, including concrete, metal, and wood, fordrillingThe following variables have been monitored: time, temperature, hole depth, shear stress on the drill bit. By contrasting the tapperness of coated and uncoated drill bits, it will determine the material's stability. Using a sample size of 80% G power, the entire experimental investigation is carried out under VMC milling machining settings. Results: Compared to using an uncoated tool, machining Delrin polymer with a new HSS PVD-coated carbide tool reduced the taperness. A statistically significant result of p=0.000 (both 2-tailed) was found for the sample t test, which is lower than the threshold of p<0.05 for taperness. Concussion: Just like the coated drill bit, the uncoated bit goes through the same procedure. You may use the uncoated drill bit to drill into a variety of materials, such as metal, wood, and concrete. Several parameters have been tracked, including elapsed time, temperature, shear stress on the drill bit, and depth of hole. The diameter, depth, and smoothness of the carbon-coated and uncoated materials will be compared. [ABSTRACT FROM AUTHOR]

The primary goal of this study is to compare the surface hardness achieved by using covered as well as uncovered carbides inputs for CNC wet turning stainless steel 304. Stainless steel 304 is the material of choice for this project, and carbide tools, both covered and unprotected are utilized for cutting. Machining characteristics such as slicing velocity, feeding rates, and depths of cutting are primarily taken into account. We evaluate the outcome after varying the parameter's values multiple times. There was an aggregate of 54 participants in the trial, with 27 from the covered tools category and 20 from the unprotected tool category. The pretest strength (G power) was 80%. The entire machining process took place in a damp setting. Compared to the unprotected tool, the covered one has a 19.4 percent reduction in surface hardness measured in microns. A statistical threshold of0.036 (p<0.05) was determined after analyzing all the collected comments using the SPSS program and plotting the resulting charts. The surface hardness was discovered to be reduced when an insertion was processed with the unique TiN coating, according to this research. In contrast, the uncovered insertion showed higher value. The SPSS research confirms what seems to be the case: the covered carbides tool consistently produces outcomes, whereas the uncovered carbides tools exhibit fluctuating outcomes. [ABSTRACT FROM AUTHOR]

Utilizing a CNC machine in a wet environment, we will evaluate the content elimination rate achieved when turning tool steel SS310 with carbide insertion treated with TiN as well as those without. In this study, SS310 tool steel material is taken as workpiece and cutting tool used is carbide inserts. The parameters are varied for the experiment at different stages to measure the response. The experiment is carried out on two groups with 27 specimens in each. On the whole 54 specimens are prepared and machined to investigate the output variable. The entire experimentation is carried out under conditions of wet machining. The level of importance was determined to be 0.032 (p<0.05) after the SPSS software was used to analyze the results and produce graphs. At smaller supply rates, the substance reduction rate was determined to be lower, but at higher feed rates, the reduction was determined to be greater. Compared to using an uncovered carbide insertion, the MRR was discovered to be greater when machining using a unique TiN covered carbides tools. Within the constraints of this investigation, it was determined that the innovative TiNcoated device outperformed the unprotected in terms of particle elimination rates, as well as the coating worked elements' characteristics were even superior. [ABSTRACT FROM AUTHOR]

To enhance the mechanical characteristics for engineering applications, this work aims to produce a unique bio composite that incorporates natural fiber. At 0, 10, 20, and 30% weight fractions, kenaf fiber (KF) is used to strengthen biopolymer poly-butylene succinate (PBS). An injection molding machine was used to create the polymer composite by adding chopped KFs to the molten PBS. A comparison is made between the prepared composite and plain PBS in terms of their machining characteristics, namely drilling. A control group consisting of unreinforced PBS and an experimental group consisting of PBS with KFs added. There were four groups given consideration. Using the G-Power calculator, three samples were analyzed for each group, each with a probability of 0.05 and a 95% confidence interval. Along with increasing their stiffness and hardness, chopped KFs added to PBS also increase their mechanical strength. Measurements are made of the amount of fiber delamination when a solid carbide tool is drilled in a vertical machining centre. A substantial difference between the groups under consideration is found in the analysis, with a significance level of 0.000 (p<0.05). This indicates that the degree of delamination rises when more KFs are included. Though its mechanical strength is greater, adding KFs to the PBS matrix, under the parameters of this investigation, results in increased delamination because the fibers pull out of the matrix during drilling. [ABSTRACT FROM AUTHOR]

The purpose of this study was to determine the effect of cutting speed on friction, vibration, and the increase in tool temperature. The research method is based on factorial. Where the cutting speed is 65-135 m/min, the depth of cut is 1 mm constant, and the feed speed is 0.09 mm/rev constant. The results of the research on low cutting conditions showed that at a cutting speed of 65 m/min, the friction force was 0.33 N, the vibration was 0.07, the tool temperature was 89.37J/min, the friction force was 13.16 N, the vibration was 0.29, the heat tool 4163.33 J/min at a cutting speed of 95 m/min. At high cutting conditions at a cutting speed of 105 m/min, a frictional force of 51.92 N, a vibration of 0.23, and a tool temperature of 2604 J/min, the friction force becomes 13.16 N, a vibration of 0.40, and a tool heat of 23364 J/min. min at a cutting speed of 135 m/min. [ABSTRACT FROM AUTHOR]

Aerospace companies frequently use carbon fiber reinforced polymer (CFRP) composites because of its remarkable material properties, including their light weight, high strength-to-weight ratio, and high stiffness. Cutting tools are crucial to the achievement of quantifiable outcomes including surface quality, tool life, and cutting force. Using tungsten carbide tools, milling operations are carried out on CFRP laminates. On a computer numerical control (CNC), all trials were carried out by adjusting the feed rate, spindle speed, and depth of cut. According to the experimental findings, the tool wear of tungsten carbide (WC-6%Co) tools is characterized by abrasive wear and rounding of the tool's cutting edge. According to my observations, the spindle speed, feed rate, and cut depth all directly correlated with tool life. The experimental and regression validation results for tool wear are remarkably similar, and the error is only about 5%. Finally, the regression model accurately predicts milling CFRP tool wear. [ABSTRACT FROM AUTHOR]

This paper highlights the importance of temperature control in the machining process and its effect on the Single Point Cutting Tool (SPCT). The study shows that the temperature increases with an increase in the depth of cut, which emphasizes the need for monitoring the temperature during the machining process. To improve the life of the tool, the study explores the use of coating on the tool. Both coated and uncoated carbide tools were used in the study, and the temperature during machining was measured using the tool-work thermocouple technique. This method is described as easy to install and inexpensive compared to other methods. The paper also explains the procedure for the working of the tool-work thermocouple and its calibration. Overall, the study highlights the importance of temperature control in machining processes, and the use of the tool-work thermocouple technique for monitoring temperature. The use of coating on the tool can also be explored as a way to improve tool life. [ABSTRACT FROM AUTHOR]

Wood-plastic composites (WPC) are becoming increasingly popular due to many benefits, including the ability to use recycled raw materials that conserve natural resources and solve environmental problems. Since the tool and the workpiece are in contact during machining, the optimization of friction processes requires significant attention. This work investigates the dry friction parameters of two different WPCs with a WC-Co hard alloy coated with PVD layers of different compositions. The tests with a tribometer were conducted using the rotating disc (WPC)-flat plate (WC-Co + PVD) scheme. The sliding distance, the normal force and the contact temperature were measured. The results of the regression analysis showed that the data obtained are best approximated by a complete second-degree polynomial model (adjusted coefficient of determination R2 >0.99). The most important factors examined are the normal force F and the contact temperature T. The coated cemented carbide tools had an average coating thickness of 1.61±0.13 µm and an increase in roughness of 10.8%. Compared to WPC-B samples, the average volumetric wear was 4.6 times higher for WPC-A samples. Due to the lower thermal conductivity of PVD coatings, heat could not be dissipated effectively in the cemented carbide substrate. With all PVD coatings, the dynamic coefficient of friction of WPC-A was 48% lower than with the uncoated blade. In contrast, the coefficient of friction of WPC-B with three different coatings was 14% higher than that of the uncoated blade. The change in roughness, coefficient of friction values, and wear rate of the PVD coatings, on the other hand, was smaller with WPC-B. With both composites, the C1-coded coating was the best for overall friction and wear effects. Surfaces were also examined using SEM, as well as EDS analysis. [ABSTRACT FROM AUTHOR]

Many of the industrial components are fabricated using the die and die sets during forging, coining, extrusion, wire drawing processes, etc. From various researchers, it is known that materials such as Carbon block steel, High hardened steel, Tungsten Oil Hardening Steel, and Carbon Steel (D Series) are used and among them, D series is extensively used in manufacturing dies due to its wear-resistant and high hardness number (>60HRC) which is very difficult to machine. The quality of the machining operation depends on the surface finish of the material. The current works is an attempt to machine D3 steel and optimize the machining parameters such as speed, feed, and depth of cut during CNC (Computer Numerically Controlled) end milling process to reduce surface roughness and machining time, using tungsten carbide as cutting tool. The experimental investigation of the surface roughness of the material has been carried out using end milling process with the help of CNC milling center. Taguchi method has been utilized for design of experiments with L16 orthogonal array, and regression analysis for mathematical modelling. Different optimization techniques such as GREY RELATION ANALYSIS, RSM and ANOVA have been utilized for comparison. Finally, the optimization results of all the three above mentioned techniques are compared and found that minimum surface roughness (Ra) of 1.0504 µm has been achieved for speed of 1400 RPM, feed rate of 950 mm/min and depth of cut of 0.06 mm; minimum machining time of 8.44 minutes have been achieved for speed of 2600 RPM, feed rate of 950 mm/min and depth of cut of 0.1mm using ANOVA technique. The result indicates ANOVA technique is a better optimization technique in comparison with other two. [ABSTRACT FROM AUTHOR]

In the manufacture of a product, there are several important things that need to be considered, such as the calculation of machining time, tool life and production costs. To know the machining time, you must know the type of work done on each component. The difference in cutting parameters is one of the factors that can affect the machining time and the rate of tool blade wear. The faster the tool wears out, the tool blade will be replaced so that the cost of the tool blade will be higher, and it will also affect the production cost. The purpose of this study was to determine the effect of cutting parameters on machining time and production costs by giving variations to these cutting parameters. and the limitation of the research in this study only discusses from the angle of drill cutting parameters, does not discuss break event points, does not discuss drill chisel geometry and does not discuss the materials used in more detail. From the results of the research and analysis carried out, it can be stated that the difference in cutting parameters greatly affects the machining time and production costs. In the type of chisel hss 1 to hss 3, the machining time is 114.17 minutes with a production cost of Rp. 844,900, 103.36 minutes with a production cost of Rp. 935,200, 95.87 minutes with a production cost of Rp. 1,033,900 and the type of chisel from carbide 1 to carbide 3, the machining time is 109.18 minutes with a production cost of Rp. 1,052,900, 93.33 minutes with a production cost of Rp. 1,105,000, 80.8 minutes with a production cost of Rp. 1,169,500. [ABSTRACT FROM AUTHOR]

When the machining process takes place, several cutting parameters such as cutting speed will determine the effectiveness of the machining process. Determining the correct combination of cutting parameters will increase the effectiveness of the machining process. Therefore, to increase the effectiveness of machining, a method is needed to determine suitable machining parameters in order to reduce excessive wear of cutting tools. By finding the effective cutting parameters, the machining process will be more efficient and effective without using unnecessary resources. Based on this, this study was conducted to analyze the wear and tear that occurs on cutting tools when turning cast iron using coated carbide chisels. the turning process is done using a CNC lathe. In this study, variations in cutting speed were used ranging from 160 m / minute, 210 m / minute, 260 m / minute, 310 m / minute and 360 m / minute. Cutting is done in a span of 10 minutes to observe and measure the wear on the cutting tool. Observations and measurements are carried out using a digital microscope. The results showed that the increase in cutting speed applied to machining resulted in increased wear of the cutting tool. This can be proven by cutting speed of 160 m / minute in 25 minutes and cutting speed of 260 m / minute it takes 15 minutes. The wear that occurs on the cutting tool is wear on the flank that occurs as a result of the abrasive process. [ABSTRACT FROM AUTHOR]

The machining of superalloy Inconel 718 has seen a rapid demand in industries due to the superiority factor of its composition which makes it corrosion resistant, wear resistant and abrasive resistant. Due to these advanced features of this alloy, the cutting tool to be used to machine becomes a challenging one. There have been several cutting tools being used in the machine but wear of the tool and high surface roughness has been observed. Two cutting tools Tungsten Carbide RYMX 1004-ML TT3540 and Ceramic AS20 hasbeen identified but the hardnesson it is failed due to the machining conditions. The cryogenic treatment of these tools can see a remarkable change in machining and bring low surface roughness and reduce tool wear. [ABSTRACT FROM AUTHOR]

In order to maximize material rate, this inquiry will examine the capabilities of physical vapour deposition, uncoated carbide tool inserts, and CNC turning of HCHC D2 Steel. Physical vapour deposition and uncoated carbide tool inserts were used to manufacture HCHC D2 Steel. It was split into two classes, each with 27 samples. Two separate tool inserts, one for the control group and the other for the experimental group, were used to machine the samples. 80% G Power was recorded. Physical vapour deposition (PVD) tool inserts with uncoated carbide inserts resulted in a decrease in surface roughness and an increase in material removal rate (P=0.085). When Novel Physical Vapor Deposition (PVD) tool inserts were utilised for machining, surface roughness was minimized and material removal rate was raised. [ABSTRACT FROM AUTHOR]

To compare the material removal rate obtained during dry turning of AISI H13 tool steel using novel TiN coated and uncoated carbide tools. Materials and Methods:The work material chosen for the study is AISI H13 tool steel of dimension 25 mm diameter and 50 mm length. The type of cutting tool selected for the turning operation is novel TiN coated and uncoated carbide tool. The designation of the cutting tool used is CNMG120408 (Make:SAAJ STEEL CORPORATION). Three input parameters are considered, cutting speed (m/min), feed rate (mm/rev), depth of cut (mmm) and each varied at three different levels for conducting L9 experimental study. Two groups of experimental study are selected (novel TiN coated and uncoated) with 27 samples per group and surface roughness is measured at three different locations taken from one experimental run and the average is utilized for roughness calculation. On the whole 54 samples are collected and measured for 2 groups. The material removal rate obtained during the study is measured and analysed. All the results obtained were analysed for its significance by SPSS software and the graphs were plotted and the level of significance was found to be 0.048 (p<0.05). Results:All the results obtained, its significance and graphs have been analyzed in SPSS software. Material removal rate obtained on the novel TiN coated carbide tool is maximized when compared with uncoated carbide tool by 3.2% during machining of AISI H13 tool steel. The samples machined with novel TiN coated carbide tool gives good result compared with uncoated carbide tool in maximizing material removal rate. [ABSTRACT FROM AUTHOR]

In this experimental research, during CNC turning of LDX2205 duplex stainless steel, the functionality of TiC coated tool and uncoated cemented carbide tool is compared, and a detailed search of the surface roughness (SR) obtained from both tools is accomplished. Materials and Methods: Cemented carbide tools with no need for a layer were in the control group and TiC-coated elements were in the experimental group. In this experiment, LDX2205 steel was used as the workpiece. Using factors such as speed of cutting, rate of feed and cut depth, 27 samples machined in a CNC turning machine based on sample size calculation done using G-power calculator. Result: During the comparison of TiC insert with the uncoated insert, the mean surface roughness value of TiC insert was 0.85330 µm and the mean value for uncoated insert was 1.05078 µm. Lower than the desired value of 0.05, the obtained critical level between the control and experimental groups is 0.039. Conclusion: Within the conditions of this experiment, the TiC tool provides a superior surface finish than just uncoated tool once duplex stainless steel is CNC shaped. [ABSTRACT FROM AUTHOR]

This research is about the comparison of novel TiN coated and uncoated carbide tools in CNC wet turning of EN31 to maximize material removal rate. Materials and methods: Work material used was EN31 tool steel and cutting tools used was novel TiN coated and uncoated carbide tools with the tool designation of CNMG120408 (Make: Widia). The three input parameters selected for present experimental study are cutting speed (m/min), feed (mm/rev) and depth of cut (mm), each parameter varied at 3 different levels and L9 experimental runs are conducted. Two groups of experimental study are selected (novel TiN coated and uncoated) with 27 samples per group. On the whole 54 samples were collected and measured for 2 groups. Result: Material removal rate obtained on the novel TiN coated carbide tool is maximized when compared with the uncoated carbide tool by 3.8% during machining of EN31 tool steel. The obtained mean value for coated carbide tool was 83.75789, and for uncoated carbide tool was 943.68333, The results are statistically analysed with the use of a SPSS software and graphs were plotted and its level of significance was found to be 0.041 (p<0.05). Conclusion: By the limitations of the study we can conclude that for the machining process of the selected hard material like EN31 steel tool, by using a novel TiN coated carbide tool, material removal removal rate has been maximized when compared to the uncoated tool during CNC turning operation. [ABSTRACT FROM AUTHOR]

When it comes to meet removal techniques, the process of turning holds paramount significance in the contemporary times. To improve the working of cutting tools at the time of operating various machining such as MMC machining and high speed machining, hard coating and cutting fluids are consider to be essential and healthy. The quality and the budget of production has got immensely affected by the development of tool used for cutting and high speed machining for hard materials. The working of multi-layer coated carbide tools while experiencing different cutting conditions of EN-24 has been included in the present work. Tool wear measurements demonstrate that Multilayer Coated carbide under wet cutting conditions offer a reasonable tool life. Surface Roughness was also found better for carbide inserts for wet conditions. The final surface appearance acquired through the multilayer carbide inserts/tools for wet conditions remained 0.224 times the surface finish achieved through the carbide tools without using lubricants. Wear rate of multilayer carbide inserts has been decreased through 0.994 times under wet conditions. MRR for multilayer coated ceramic inserts in case of dry cutting conditions was found 0.754 times the MRR of carbide inserts under wet conditions. It has also been found that the turning of rigid material is upgraded by using multilayer coated carbide inserts in the wet environment when compared to that of dry cutting conditions. [ABSTRACT FROM AUTHOR]

Minimum quantity lubrication is a widely used technique in industrial applications to minimize the amount of cutting fluid that reduces manufacturing costs. In this experiment, MQL is used in the face milling operation of AISI-52100 steel using carbide tool inserts. Multi response optimization of response parameters like temperature (T) and surface roughness (Ra) has been studied using Taguchi coupled with grey relational analysis (GRA). The effect of input process variables such as cutting velocity (Vc), coolant flow rate (Q), and feed per revolution (f) on Ra and T of the cutting zone was analyzed. ANOVA analysis found that f and Vc were the most dominant parameters for Ra and T. The optimal conditions for the T and Ra were at cutting velocity 160 rpm, the Q at 120 ml/hr and feed per revolution at 0.1 mm/rev. [ABSTRACT FROM AUTHOR]

Metal cutting is one of the most efficient methods of metal processing. At the same time, productivity is largely determined by the material and design of the cutting tool. The use of hard wear-resistant coatings on the cutting tool increases its performance. Carbide cutting tools are used for machining machine parts made of complex alloyed materials. Application of protective composite nanostructured coatings on carbide cutting tools increases the service life of cutting tools several times. The coating on their base protects the cobalt binding of carbide alloys. The low thermal conductivity of the composite nanostructured titanium carbide coating means that the heat generated when cutting workpieces is mostly transferred to the chips so that the tool does not become overheated. This is important when machining difficult alloyed, hard-to-machine, ductile materials for which the temperature at the contact zone of the cutting edge and the machined material reaches up to 900°C. The adhesive interaction of the composite nanostructured coating with the substrate material is of no small importance in selecting the coating composition. From this point of view, carbide titanium coatings have good compatibility with carbide cutting tools. Along with this, the study of ion-plasma composite nanostructured coatings based on TiC carbides is relevant. The study results of the composition and properties of vacuum composite nanostructured coatings based on titanium carbides obtained by the ion-plasma method are presented. Studies of the chemical composition, electronic and atomic structure of composite nanostructured coatings based on Ti carbides were carried out using the HREELS, XPS and AES method and based on experimental studies of composite nanostructured TiC coatings, the p – T – x diagrams for TiC were refined. [ABSTRACT FROM AUTHOR]

Machining experiments in the form of turning operation are performed on round specimens of MDN 350 Alloy. Titanium coated Carbide tool inserts are used and CNC lathe machine is employed. Tool inserts flank wear is measured at various selected values of cutting speed and feed rate, while depth of cut is maintained at constant value. Proper surface finish of permissible value is ensured throughout the experiments. Significant machining outcomes viz. (i) Tool-Life, (ii) Machining Rate and (iii) Machining Cost are evaluated based upon tool-wear and machining time. Contour plots are developed for the aforementioned outcomes in order to recognize the optimum values of cutting speed and feed rate in the machining of the subject alloy. Estimated optimum values are verified in experimental validation with tool-life test. It is observed that tool life has significantly improved, whereas machining rate has marginally improved while machining cost has slightly reduced at optimum values of machining parameters. [ABSTRACT FROM AUTHOR]

This paper presents the image-based tool wear detection using an image processing approach for face milling operation to prevent the workpiece surface roughness which is affected by the worn cutting tool. Based on the previous research, it was found that lack of monitoring of detection tool wear percentage to determine the condition of the cutting tool which the cutting tool needs a replacement or can continue used for the machining process. When the workpiece machining length increases, the machining time increases. The cutting requirement will increase based on their tool lifespan which will increase the percentage of tool wear rapidly. Therefore, the tool wear monitoring procedures applied after several milling processes such as image-based tool wear percentage detection by using an image processing approach for uncoated carbide tools, tool life criteria based on flank wear according to ISO 8688-1:1989 for uncoated carbide tools, and surface roughness quality according to ISO 4288:1996 for mild steel (AISI 1045) workpiece. The results indicated that the percentage of wear increase up to 50 percent with the cutting length and machining time. The surface roughness of the test material also increased linearly with increases in cutting length and machining time. In conclusion, the image-based tool wears percentage value detection by using an image processing approach has a potentially sustainable and economical expenditure for determining tool life criteria to sustain the machining performance. [ABSTRACT FROM AUTHOR]

Aluminium alloys are commonly used in the aerospace, automobile and electricity transmission industries due to its excellent strength to low weight ratio. The demand of high accuracy machining in the market today has made the optimizing of the machining parameters an important aspect of machining. Aluminium alloy Al7075-T651 is a ductile material. In continuous machining operation like turning, high amount of friction and heat is generated. This may cause the workpiece's material to adhere to the rake face of the cutting insert and lead to the built-up edge (BUE) formation. This BUE will detach and adhere to the chips in a way the surface roughness of the workpiece would be affected. This project is focusing on the machinability of aluminum alloy Al7075-T651 by measuring the performance of KW10 uncoated carbide cutting tool in terms of flank wear, surface roughness of the machined surface, wear mechanism and volume of material removed. The turning experiment was conducted in dry condition. The cutting speed range was 250 and 450 m/min whereas the feed rate range was 0.05 and 0.15 mm/rev. The depth of cut was kept constant at 1 mm. The results showed that the higher cutting speed and feed rate produced higher flank wear progression and higher surface roughness reading (Ra). The adhesive and abrasive wear can be seen through the SEM for all sets of parameters. It was identified that higher cutting parameters removed higher amounts of volume material with shorter tool life. [ABSTRACT FROM AUTHOR]

The efficiency of using cutting tools is a serious concern in the production process. The efficiency of using cutting tools can be interpreted as an effort to slow down the tool wear. Owing to its direct impact on the surface quality and machining economics, tool wear is commonly used to evaluate the performance of a cutting tool. Also, fast-wearing tools must be replaced and that takes time. Speed and target-oriented production processes certainly cannot tolerate. Therefore, this study revealed the effect of cutting speed on the type of wear produced in the threading process made from JIS G 4051 Grade S45C Steel. This study used an experimental method to analyze the effect of cutting speed on the type of tool wear. This experiment used carbide insert tool with the Mitsubishi brand type MMT16ERAG60-EDP:262182. The result of this experiment showed that cutting speed affects the type of wear produced. The greater the cutting speed, the more varied the type of wear produced. The size of each type of tool wear produced is also getting bigger as the cutting speed is getting bigger. [ABSTRACT FROM AUTHOR]

In manufacturing of tools coated tools has contributing to the metal cutting process in terms of improvement in tools life , faster cutting speed and in terms of good surface finish, which is a growing issue now as a consequence of advancement in the cutting tool business. The cutting process can be can be done at either a constant surface speed (sfm, m/min.) or constant RPM. In the dry cutting process, high cutting temperatures are generated, resulting in a high wear rate of cutting instruments. TiAlN coated carbide tools are utilised in this study to machine the mild steel work piece at the appropriate process parameters. The effect of TiAlN coating thickness on wear resistance was investigated. In this study wear testing Frictional force , coefficient of frictional , and pin temperature on both coated as well as uncoated carbide tools were performed, and the results were analysed. The results of the tests reveal that coated tools have low wear rates and friction coefficients, which enhances machining productivity. [ABSTRACT FROM AUTHOR]

The effect of parameters during turning such as spindle speed, feed rate, and depth of cut on the surface roughness was studied under dry and flood lubrication conditions. The turning process was performed on aluminum 6061 on a Lathe machine and optimised using Taguchi Orthogonal Array (OA) experimental method. The array used was L9. The turning operation used Tungsten Carbide as the cutting tool. Under flood lubrication, the cutting fluid used was Shell Dromus B, a soluble oil. The surface roughness was measured in terms of arithmetical mean value, Ra, using Mahr GD25 machine. Analysis was performed through mean S/N ratio and Analysis of Variance (ANOVA). It was found that the feed rate affects the surface roughness the most, with a contribution of 84% and 79% under dry and flood lubrication respectively, followed by spindle speed and depth of cut. There is a reduction of 27.2% in surface roughness when turning was performed under flood lubrication. The best combination of parameters to produce a good surface finish is by keeping a low feed rate with high spindle speed. The optimum turning condition was found when turning at spindle a speed of 1000 rpm, feed rate of 0.1 mm/rev, and depth of cut of 2 mm. [ABSTRACT FROM AUTHOR]

In this paper, we studied lathe machining characteristics of hard materials that have been softening with an annealing process. We utilized carbide cutting tools with variations of machining parameters and machining perform without cooling water. The data was obtained experimentally by giving machining variables of spindle speed of 750 rpm, 1000 rpm and 1250 rpm; feed (f) of 0.035 mm/rev, 0.05 mm/rev, 0.085 mm/rev and 0.18 mm/rev; and cutting depth of 0.5 mm. The materials used were high hardenability antifriction bearing steel ASTM A 485 and annealing process was carried out at a temperature of 1000 °C. After the machining process, surface roughness (Ra) measurement was performed using Mitutoyo Surface Tester 301. Measurements were performed on both materials which were annealed and without annealing as a reference. The results show that annealing treatment increased the surface roughness. The Ra value for material without annealing was 1.150 µm to 2.865 µm and annealed material of 1.394 µm to 6.999 µm. Maximum roughness occurred in spindle speed of 1000 rpm for material without annealing, while annealed material it happened at 750 rpm. On the other hand, minimum roughness occurred in spindle speed of the 750 rpm for material without annealing, while annealed material happened at 1250 rpm. In conclusion, this indicated that the softer material due to annealing treatment will largely depend on spindle speed choice on produced high quality (low surface roughness) in machining process especially on dry machining. [ABSTRACT FROM AUTHOR]

Milling process is a kind of machining that allows modeling in various materials such as composites, metal, plastic, and wood etc. with complex forms and trimming pieces and in the meantime the chips elimination and processingresidues. This article investigates the machining parameter optimization for a face milling operating in a vertical CNC milling machine with a workpiece material of aluminium alloy 7075 and cemented carbide as a cutting tool. Various experiments are performed with the variation of input processing parameters such as spindle speed (Ss), feed rate (Fr), and the cutting depth (Dc). In addition, the impact of input process parameters is examined using the Taguchi design approach, which also optimizes the machining process parameters and construct the association among them w.r.t. the output response characteristic called surface roughness (SR), and material removal rate (MRR), where the optimal combination for the improved MRR is obtained at Ss of 3500 rpm, Fr of 400 mm/min and Dc of 0.3 mm and enhanced surface finish is about 3500 rpm, 400 mm/min, and 0.2 mm of Ss, Fr and Dc, respectively. [ABSTRACT FROM AUTHOR]

The technology of application of multicomponent functional diffusion coatings from the medium of low-melting liquid-metal solutions on a carbide cutting tool of the WC-TiC-Co and WC-Co type is described in detail. It was found that the thickness varies with the exposure time and temperature and ranges from 8 to 27 microns on alloys of the WC-Co type; and from 9 to 29 microns on alloys of the WC-TiC-Co type. As a result of X-ray spectral analysis, it was revealed that the elemental composition of the coating depends on the composition of the base on which it is applied. The maximum concentration of elements in the surface layer of the coating is: Ni 1.23%, Cu 4.14%. The Ti content in the coating is in the transition layer and is 23.96%. Diffusion coatings obtained on hard alloys are characterized by a smooth change in the concentration of elements along the thickness. [ABSTRACT FROM AUTHOR]

Cutting fluids having a significant role in machining operation and have a great positive impact, especially on the tool life, tool wear and surface roughness of the workpiece. Investigation on end milling of hardened steel AISI 1045 using coated solid carbide cutting tool under different coolant conditions was carried out experimentally. Experimented work involved three different coolant concentrations which are 3%, 6%, and 9%, with a different cutting speed of 35m/min and 50m/min. The depth of cut and feed rate was kept constant at 4mm and 0.05mm/tooth, respectively. The machining performance was evaluated based on the effect of tool wear, tool life and surface roughness. Analysis of recorded data shows that tool performance during machining is dependent on coolant concentration and cutting speed. Coolant with 3% concentration gave the best overall performance as an effective combination of cooling and lubrication functions during machining. Longer tool life when machining at cutting at a higher cutting speed of 50mm/min, due to the reduced amount of the build-up edge (BUE) on the cutting tool. [ABSTRACT FROM AUTHOR]

This paper discusses the effect of cutting parameters on the chip formation when machining Aluminum Alloy 7075-T6 with carbide tools under high-speed machining. The cutting condition applied in this study were dry and near dry conditions. Full factorial design with 3 factors and 2 level was used. The cutting speed, feed rate and axial depth of cut used are 500 m/min and 600 m/min, 0.12 mm/tooth and 0.15 mm/tooth and 1.40 mm and 1.70 mm respectively. The near dry cutting is also known as Minimum Quantity of Lubricant (MQL). The flow rate applied was 100 mL/H. This experiment shows that the size of chip much depends on the feed rate and depth of cut. Smaller chip was observed at lower feed rate and lower depth of cut. Cutting speed has no significant impact on the size of chip. Chips produced under MQL machining have less burn marks. This is a strong evidence that the MQL can reduce the heat generated at the cutting zone. [ABSTRACT FROM AUTHOR]

Evaluation of the performance of two nanofluids (γ-Fe2O3 and xGnP) was investigated in hard turning of AISI 420 stainless steel (48 ±2 HRC) using coated carbide tools (KC5010) under minimum quantity lubrication. The investigation considered the tool life, cutting force and surface roughness responses at medium cutting speed and feed rate (135 m/min, 0.20 mm/rev) and constant depth of cut (0.2 mm). The concertation of nanofluids are 0.4% (1.6 g), 0.8% (3.2 g), and 1.2% (6.4 g) by weight of γ-Fe2O3 and xGnP. The results revealed the overall better performance of γ-Fe2O3 compared to xGnP. The better performance of γ-Fe2O3 was achieved at 0.8% concentration as it leads to the lowest surface roughness (0.18 μm), and cutting force (FX= 195 N) and highest tool life (8.31 min). However, the 0.4% of xGnP lead to the worst performance as it had the cutting force (FX= 285 N) and lowest tool life (3.27 min) while, highest surface roughness (0.26 μm) for both 0.4 γ-Fe2O3 and 0.8 xGnP. It is expected that this study finishings will improve the cutting condition which leads to the achievement of good geometry, enhancement of environmental friendliness, improvement of surface integrity, saving of time and reduction of cost in the manufacturing industries of hardened materials. [ABSTRACT FROM AUTHOR]

Titanium alloys are metals obtained by the homogeneous mixture of titanium and other chemical elements (metal or non-metalloids). Titanium alloy (Ti-6Al-4V) has been widely used in aerospace and medical applications and the demand is ever growing due to its applications. In the present work the basic material used is Titanium alloy (Ti-6Al-4V) and micro grooves are prepared on the carbide tool with the help of LASER and coated with TiN (PVD method of coating). The experiment is done on the CNC turning machine by varying the input parameters such as depth of cut, cutting speed and feed rate. The different cutting conditions like dry, wet with uncoated carbide tool and their results are compared with the PVD coated carbide tool. The output parameters that are checked during this work are chip formation, surface roughness, temperature, MRR and vibration with three set of machining parameters. The result is showed that good surface finishing with less temperature formation is observed with PVD coated carbide tool. This type of machining will be encouraged as an eco-friendly process. [ABSTRACT FROM AUTHOR]

The need of machining is to produce good quality products in low cost. This objective can be attained by selecting proper machining parameters, tool geometry and tool materials. In this manuscript, the influence of various process parameters on machining a grey cast iron with multilayer coated carbide tool under wet cutting condition were studied. The experiment has been carried out for turning operation at five different spindle speeds (rpm) and three feeds with 2.5 mm constant depth of cut. Multilayer (TiN+TiCN+Al2O3) carbide tool is the cutting tool used for this work, the cutting conditions were 400, 450, 500, 550 and 600 rpm spindle speeds and 0.20, 0.23 and 0.27 mm / rev feed rates. The experimental results are analyzed and optimum process parameters are find out with the help of conventional graphs. The optimum values obtained are 500 rpm; 0.23 mm/rev; and 1.2 mm (nose radius) for the work piece-cutting tool combination were used. [ABSTRACT FROM AUTHOR]

The quality of the machined surface is considered as one of the most important characteristics in machining due to the relation between customers' requirements and high performance demands. Machining process, including the resulting surface finish, is significantly influenced by chips generated. Minimum quantity of lubrication (MQL), which sprays small amount of cutting fluid to the cutting zone area with the aid of compressed air, is an ecofriendly cutting fluid application technique with similar advantage to conventional flood cooling. This paper investigates the effect of cutting speed (100 – 170 m/min) and feed rate (0.16 – 0.24 mm/rev)) on chip morphology when turning a hardened AISI 420 stainless steel under MQL using castor oil. Chip forms, thickness, and hardness were observed. It was found that continuous chip was generated at low cutting speed at all feed rates and saw toothed or segmented chips are produced at medium and high cutting speeds and feed rates. Cutting speed and feed rate influenced the thickness of the chip generated. [ABSTRACT FROM AUTHOR]

Tool wear is one in all the foremost necessary issues in cutting Ti alloys thanks to the high-cutting temperature and robust adhesion. Recently, the high-speed machining method has become a subject of nice interest for Ti alloys, not solely as a result of it will increase material removal rates, however, additionally as a result of it will completely influence the properties of the finished work piece. However, the method could lead to the rise of cutting force and cutting temperature which can accelerate tool wear. In this paper, turning experiments of Ti-6Al-4V alloy were conducted at high speeds using both uncoated and coated carbide tools. The obtained results show that the cutting force will increase considerably at higher cutting speed whether or not the cutter is an uncoated inorganic compound or TiN/TiAlN physical Vapour deposition (PVD)-coated inorganic compound. For uncoated carbide tools, the mean flank temperature is almost constant at a higher cutting speed, and no obvious abrasion wear or fatigue can be observed. However, for TiN/TiAlN PVD-coated carbide tools, the mean flank temperature always increases as the increase of cutting speed, and serious abrasion wear can be observed. In conclusion, the cutting performance of uncoated inserts is comparatively higher than TiN/TiAlN PVD-coated inserts at a better cutting speed. [ABSTRACT FROM AUTHOR]

Cobalt chrome molybdenum (CoCrMo) alloy is among the biomedical materials which is considered difficult to cut materials due to their combination of high strength, high toughness, high wear resistance, and poor thermal conductivity. In this study, high speed end milling (HSEM) was performed experimentally to access the machinability of CoCrMo alloy using solid coated and uncoated tools at different cutting speeds of 125, 140 and 155 m/min under the minimum quantity lubricant (MQL) strategy. The axial and radial depth of cut were kept constant 4 mm and 1.5 mm respectively throughout the machining tests. The tool wear, tool life and tool wear mechanism were recorded and analyzed accordingly. It was observed that higher cutting speed significantly reduces the tool life due to rapid tool wear. Coated carbide tool performed better than uncoated carbide tool in terms of tool life for every cutting speed. It was also found that chipping, adhesion and cracks were the dominant wear mechanisms occurred on the cutting edge when high speed end milling of CoCrMo biomedical material. [ABSTRACT FROM AUTHOR]

Tooling costs is one of the causes for major concern in manufacturing industries. To overcome this problem by utilizing a few strategies like cutting liquid, ideal Machining parameters, surface and heat treatment. Cryogenic treatment is generally used to enhance tool life. In this study impacts of distinctive Soaking times of Deep cryogenic treated inserts on turning of EN8 steel. The CNMG inserts were cryogenically treated at -196°c for 36 hours with interval of 12 hours. The cutting speeds are varied from 80 to 140 m/min, with interval of 20m/min. likewise feed rates also differed from 0.05 to 0.2 mm/rev with interval of 0.05 mm/rev. depth of cut has been varied for 1.4 to 2.0 mm with interval of 0.2mm dry turning were also compared. From the cryogenic treatment micro-harness of the inserts were increased in all the holding time. The highest hardness value is obtained in 24 hour cryogenic treated inserts. The microstructures of cryogenic treated and untreated CNMG inserts are determined. Materials surface roughness is measured by varying the machining condition. [ABSTRACT FROM AUTHOR]

Crank is an important part of the bed to raise and lower the bed. Crank consists of outer pipes, threads, and nuts. Based on observations, crank defect mostly occurred in the production process of thread profiles. The defect is caused by variance in diameter minor and diameter major. This can make the crank stuck. The problem is caused by the carbide insert tool used has worn out because the optimal time of use of the tool has not been considered and process stages that are not in accordance with quality assurance management. The purpose of this research is to reduce defects in the crank production plan and prevent defects after usage by consumers. This paper provides recommendations for improvements in production process management. Lean six sigma aims to improve production line efficiency by reducing production costs, eliminating defects and establishing capability process so that the company can produce high quality product. In this paper define, measure, analyze, improve, control (DMAIC) is used as a lean six sigma tool to solve the problem. Therefore, DMAIC is used to identify, measure, and discover the causes of the problem and to suggest some solutions to control and reduce the defect. The use of simple mathematical model is proposed to determine the optimal used time of the carbide insert tool. The results show that the capability process increases from 3.8 to 4.1 sigma which lead to cost saving from 25-40% to 15-25% quality cost. [ABSTRACT FROM AUTHOR]

The paper aims for presenting systematic review of all aspects to be considered for coatings in dry machining. Many have tried machining processes on various components with zero use of cutting fluids to avoid hazardous environments. The process of machining the components without use of cutting fluids is called as dry machining. Our primary aim is to focus on areas and applications where dry machining is used. The various coatings on tools used during dry machining has been discussed along with their properties considering temperature sustainability, modifications in tool geometry for better performance during machining. The tools used in turning process undergo very high thermal loads as well as abrasive and adhesive loads. The coatings on tools provides thermal barrier between tool and work piece thereby decreasing thermal loads as well as increasing tool life There are coatings like TiAlN, CrN, CrAlN, etc which can be deposited on inserts before machining. Most widely carbide inserts with suitable coatings are used for dry turning operations. [ABSTRACT FROM AUTHOR]

The present study is mainly focused on the cutting performance of the micro-scale textured carbide tools while turning AISI 304 austenitic stainless steel under dry cutting environment. The texture on the rake face of the carbide tools was fabricated by laser machining. The cutting performance of the textured tools was further compared with conventional tools in terms of cutting forces, tool wear, machined surface quality and chip curl radius. SEM and EDS analyses have been also performed to better understand the tool surface characteristics. Results show that the grooves help in breaking the tool-chip contact leading to a lesser tool-chip contact area which results in reduced iron (Fe) adhesion to the tool. [ABSTRACT FROM AUTHOR]

In this research study, it presents the influences of drilling parameters on the delamination factor during the drilling of woven kenaf fiber reinforced epoxy composite laminates when using the carbide drill bits. The purpose of this study is to investigate the influence of drilling parameters such as cutting speed, feed rate and drill sizes on the delamination produced when drilling woven kenaf reinforced epoxy composite using the non-coated carbide drill bits. The damage generated on the woven kenaf reinforced epoxy composite laminates were observed both at the entrance and exit surface during the drilling operation. The experiments were conducted according to the Box Behnken experimental designs. The results indicated that the drill diameter has a significant influence on the delamination when drilling the woven kenaf fiber reinforced epoxy composites. [ABSTRACT FROM AUTHOR]

Drilling is a very common machining operation to install fasteners for assembly of laminates Drilling of Carbon Fiber Reinforced Plastic (CFRP) and Glass Fiber Reinforced Plastic (GFRP) composite laminate materials are different from that of convention materials that causes excessive tool wear and edge delamination. This paper reports on the tool geometry, cutting speed and feed rate. In this work two composite materials CFRP-G926 and Glass-7781 composite materials of varying thickness are drilled to investigate the effect of feed rate, and cutting speed. The study mainly focused on drilling laminates specimen of varying thickness 9 mm, 9.6 mm and 12 mm by using a single shot solid carbide step drill K44. The drilling is performed from lower to higher feed rate and cutting speed to investigate the hole quality, bottom top edge delamination, fiber breakages and local cracks. The work performed shows that a proper combination of tool geometry, cutting speed and feed rate can help to reduce the occurrence of delamination. [ABSTRACT FROM AUTHOR]

Thin-wall components as usually applied in the structural parts of aeronautical industry require significant challenges in machining. Unacceptable surface roughness can occur during machining of thin-wall. Titanium product such Ti6Al4V is mostly applied to get the appropriate surface texture in thin wall designed requirements. In this study, the comparison of the accuracy between Response Surface Methodology (RSM) and Artificial Neural Networks (ANN) in the prediction of surface roughness was conducted. Furthermore, the machining tests were carried out under Minimum Quantity Lubrication (MQL) using AlCrN-coated carbide tools. The use of Coconut oil as cutting fluids was also chosen in order to evaluate its performance when involved in end milling. This selection of cutting fluids is based on the better performance of oxidative stability than that of other vegetable based cutting fluids. The cutting speed, feed rate, radial and axial depth of cut were used as independent variables, while surface roughness is evaluated as the dependent variable or output. The results showed that the feed rate is the most significant factors in increasing the surface roughness value followed by the radial depth of cut and lastly the axial depth of cut. In contrary, the surface becomes smoother with increasing the cutting speed. From a comparison of both methods, the ANN model delivered a better accuracy than the RSM model. [ABSTRACT FROM AUTHOR]

The manufacturing industry aims to produce many products of high quality with relatively less cost and time. Different cutting parameters affect the machining performance of surface roughness, cutting force, and material removal rate. Nevertheless, a few studies reported on the effects of sustainable factors such as power consumed, cycle time during machining, and tool life on the dry turning of AISI 316. The present study aims to evaluate the machining performance of coated carbide in the machining of hard steel AISI 316 under the dry turning process. The influence of cutting parameters of cutting speed, feed rate, and depth of cut with their five (5) levels is established by a central composite design. Highly significant parameters were determined by analysis of variance (ANOVA), and the main effects of power consumed and time during machining, surface roughness, and tool wear were observed. Results showed that the cutting speed was proportional to power consumption and tool wear. Meanwhile, insignificant to surface roughness, feed rate most significantly affected surface roughness and power consumption followed by depth of cut. [ABSTRACT FROM AUTHOR]

The machining of superalloy parts still an area not very clear in mechanical manufacturing. It is found to be used in particular areas such as gas turbine, rocket engine, space ships, nuclear reactors, and pumps. The machining of Inconel 738 superalloy has been studied in this context, with the aim to understand the wear behavior with carbide inserts coated with TiN and in order to optimize the cutting parameters before starting the production. The wear behavior of the inserts during the machining process of a very tough austenitic superalloy is unclear, and requires a series of well determined tests. The life of the insert under high stress such as pressure, cutting speed, high temperature, in a hostile zone and in contact with a very tough and harder material is determined. The generated process of wear is very complex, because it is followed by physico-chemical phenomenon appearing on the contact surfaces between the active part of the tool and workpiece.The lifetime of machine tools often depends on the tribological characteristics of the material couples (cutting tool / material to be machined). It has been shown that the most influential parameter is the coating, then comes the sliding speed. A relationship between the wear VB and the roughness Ra is proposed to collect information on the cutting edge and the quality of the tool by measuring the roughness. For wear measurement, an indirect method is used in coupling a Touptek photonics camera to capture and Ttoupview analysis software. [ABSTRACT FROM AUTHOR]

The austempered ductile iron (ADI) material is widely used for automotive and structural applications. However, it is considered a difficult to machine material due to its strain hardening behavior and low thermal conductivity characteristics; thus delivering higher mechanical and thermal loads at the tool-chip interface, which significantly affects the tool wear and surface quality. The paper thus overviews the cutting performance and wear behavior of different cutting tools during dry drilling of newly produced ADI material. Cutting performance was evaluated in terms of specific cutting energy, workpiece surface integrity and tool wear behavior. Tool wear behavior shows crater wear mode and workpiece adhesion. The surface alteration at the machined subsurface was confirmed from the hardness variation. Multilayer (Ti,Al,Cr)N coated tool shows improved cutting performance and wear behavior due to its enhanced tribological adaptability as compared to another PVD coating leading to the reduction in specific cutting energy by 25%. [ABSTRACT FROM AUTHOR]

Although the turning process has been widely studied and is well-known, some limitations exist in the processing of certain materials due to an absence of their characterization. Such is the case of austenitic stainless steels, which in spite of being materials of great economic and technological value, their behavior in machining is still not well understood in some aspects. In industry there is not enough reliable and up-to-date technological data about austenitic stainless steels, especially when considering the state of the art in technology development where cutting speeds are higher and higher. In this paper a mechanistic model for cutting force prediction is developed; expressions for the specific coefficients of cutting are determined that characterize the behavior of austenitic stainless steels turning at high cutting speeds using coating tungsten carbide tools. [ABSTRACT FROM AUTHOR]

EDM is a known process for machining of hard and brittle materials. Due to its noncontact and nearly forceless behaviour, it has been introduced into micro manufacturing and through constant development it is now an important means for producing high-precision micro geometries. One restriction of EDM is its limitation to electrically conducting materials. Today many applications, especially in the biomedical field, make use of the benefits of ceramic materials, such as high strength, very low wear and biocompatibility. Common ceramic materials such as Zirconium dioxide are, due to their hardness in the sintered state, difficult to machine with conventional cutting techniques. A demand for the introduction of EDM to these materials could so far not be satisfied because of their nonconductive nature. At the Chemnitz University of Technology and the Fraunhofer IWU, investigations in the applicability of micro-EDM for the machining of nonconductive ceramics are being conducted. Tests are undertaken using micro-EDM drilling with Tungsten carbide tool electrodes and ZrO2 ceramic workpieces. A starting layer, in literature often referred to as 'assisting electrode' is used to set up a closed electric circuit to start the EDM process. Combining carbon hydride based dielectric and a specially designed low-frequency vibration setup to excite the workpiece, the process environment can be held within parameters to allow for a constant EDM process even after the starting layer is machined. In the experiments a cylindrical 120 μm diameter Tungsten carbide tool electrode and Y2O3- and MgO- stabilized ZrO2 worpieces are used. The current and voltage signals of the discharges within the different stages of the process (machining of the starting layer, machining of the base material, transition stage) are recorded and their characteristics compared to discharges in metallic material. Additionally, the electrode feed is monitored. The influences of the process parameters are analysed with regard to the discharge type, electrode wear and process speed. Using the found parameters, micro geometries can be successfully machined into nonconductive Y2O3- and MgO- stabilized ZrO2 ceramic by means of micro-EDM. [ABSTRACT FROM AUTHOR]

This paper presents the simulation work performed to study an innovative process called micro-Laser Assisted Machining (μ-LAM). μ-LAM is being used for machining hard and brittle semiconductor and ceramic materials such as Silicon Carbide. Numerical simulations were carried out using the commercial software AdvantEdge Version 5.4. The cutting tool is modeled as a single point diamond tip. The workpiece material (4H-SiC) is heated locally during the actual machining process by a laser beam, which passes through the diamond tool tip. The workpiece is heated beyond the thermal softening point in order to study the effect of increased temperature on the machining process. The initial work started with an approximate thermal softening curve to ensure that thermal effects can be incorporated in the simulation model. A new thermal softening curve was developed based upon experimental data and implemented in the material model. A thermal boundary was provided on the workpiece top surface to simulate the effect of laser heating. In all three cases the chip formation was observed and the changes in cutting and thrust forces were evaluated. The simulation results indicate a significant decrease in machining forces if Silicon Carbide is heated and thermally softened thus demonstrating the benefits of the μ-LAM process. [ABSTRACT FROM AUTHOR]

Machining of Ti-6Al-4V ELI becomes more interested topic due to extremely weight-to-strength ratio and resistance to corrosion at elevated temperature. Quality of machined surface is presented by surface roughness, surface texture and damages of microstructure of titanium alloys. The turning parameters evaluated are cutting speed of 55-95 m/min, feed rate of 0.15-0.35 mm/rev, depth of cut of 0.10-0.20 mm and tool grade of CVD carbide tools. The results show the trend lines of surface roughness value are higher at the initial machining and the surface texture profile has a strong correlation with the feed rate. At the machining condition of cutting speed of 95 m/min, feed rate of 0.35 mm/rev and depth of cut of 0.10 mm produced the with layer with thickness of 2.0 μm. [ABSTRACT FROM AUTHOR]