Comparative Analysis on the Wear Performance of New and Reconditioned Ceramic Cutting Tools When Machining Nodular Cast
- PDF / 1,420,007 Bytes
- 10 Pages / 593.972 x 792 pts Page_size
- 51 Downloads / 199 Views
JMEPEG https://doi.org/10.1007/s11665-020-05319-2
Comparative Analysis on the Wear Performance of New and Reconditioned Ceramic Cutting Tools When Machining Nodular Cast Iron GGG-60, with Lubrication of Two Types of Fluids Joa˜o Roberto Sartori Moreno
, Andre´ Alonso Ribeiro, and Janaina Fracaro de Souza Gonc¸alves
Submitted: 28 June 2020 / Revised: 12 October 2020 / Accepted: 25 October 2020 The advantages and disadvantages of reusing machining tools were evaluated in this research, because through the monitoring of insert wear it was possible to compare the performance between the new and reconditioned tools when machining nodular cast iron GGG-60. In this way, the material was milled with a new tool, reconditioned tool with SiAlON, silicon nitride based ceramic insert. In the study, two cutting parameters were considered, one recommended by the tool manufacturer and the other optimized during pretests. Aiming at a sustainable process, a semi-synthetic soluble mineral oil and a vegetable oil were used as the cutting fluid for the study. Thus, through the Action 6.0 software, a complete factorial experimental design was carried out, in three independent variables and two levels, observing the tool life and the wear mechanisms in the response. Therefore, it was observed that the main mechanism of abrasion and adhesion wear, both for the new tool and the reconditioned one, generated a noticeable flank wear. However, the best statistically obtained interaction for the process variables was found for new tools in cutting parameter P1 and semi-synthetic Rocol Ultracut cutting fluid. Keywords
ceramic insert, flank wear, nodular GGG-60, silicon nitride-Si3N4, tool reconditioned
1. Introduction Currently, some companies are using reconditioned cutting tools in order to reduce production costs. One of the great difficulties to consolidate this practice is the fear that reconditioned tools do not have the same cutting capacity compared to new ones, highlighting that some tool providers count on tool reconditioning programs and, according to Kennametal (Ref 1), there is elimination of premature failures and recovery of inserts due to the performance of the nozzle that maintains the same precision throughout the repeated cutting cycles, with an approximate 50% savings. With the increasing need of the market to reduce production costs, automated machining is a key feature for the manufacturing industries. The main losses of material and machine time are the result of continuous degradation of the edges of the machine tool (Ref 2). On the other hand, it is very important to select the materials of the cutting tools and the cutting parameters for machining CGI (compacted graphite iron), as the milling speed, feed per tooth in the milling force greatly influence the ceramic life and Joa˜o Roberto Sartori Moreno, Andre´ Alonso Ribeiro, and Janaina Fracaro de Souza Gonc¸alves, Federal Technological University of Parana´ (UTFPR), Corne´lio Proco´pio Campus, Alberto Carazzai Av., 1640, Corne´lio Proco´pio, PR CEP 86300-000, Brazil. Co
Data Loading...
