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Research Papers

The Correlation of the Volumetric Wear Rate of Turning Tool Inserts With Carbide Grain Sizes

[+] Author and Article Information
Mathew A. Kuttolamadom

Texas A&M University,
College Station, TX 77843
email: mathew@tamu.edu

M. Laine Mears

Clemson University—International Center for Automotive Research,
Greenville, SC 29607 email: mears@clemson.edu

Thomas R. Kurfess

Georgia Institute of Technology,
Atlanta, GA 30332
email: kurfess@gatech.edu

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received March 12, 2014; final manuscript received July 24, 2014; published online November 26, 2014. Assoc. Editor: Z. J. Pei.

J. Manuf. Sci. Eng 137(1), 011015 (Feb 01, 2015) (8 pages) Paper No: MANU-14-1110; doi: 10.1115/1.4028129 History: Received March 12, 2014; Revised July 24, 2014; Online November 26, 2014

The objective of this paper is to analyze the effect of different carbide grain sizes on the tool material volume worn away from straight tungsten–carbide–cobalt (WC–Co) turning inserts. A previously developed metrology method for assessing the tool material volume worn away from milling inserts is adapted for quantifying the volumetric tool wear (VTW) of turning inserts. Controlled turning experiments are conducted at suitable points in the feed-speed design space for two sets of uncoated inserts having different carbide grain sizes. Three levels of Ti–6Al–4V stock removal volumes (10-cm3 each) are analyzed. For each insert, the tool material volume worn away (in mm3) as well as the three-dimensional (3D) wear profile evolution is quantified after each run. Further, the specific volumetric wear rate and the M-ratio (volume of stock removed to VTW) are related to the material removal rate (MRR). The effect of carbide grain size on VTW is examined using scanning electron microscopy and elemental analysis. Finally, the inverse dependence of the M-ratio on MRR enables the definition of actual usable tool life in terms of its efficiency in removing stock, rather than being based on a tool geometry related metric.

FIGURES IN THIS ARTICLE
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Copyright © 2015 by ASME
Topics: Wear , Grain size , Milling , Turning
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References

Figures

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Fig. 1

An inconsistent wear quantification scenario [8]

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Fig. 2

Adaptation of the VTW metrology for turning inserts: (a) worn turning tool surface, (b) point cloud data, (c) 3D point-cloud model of worn crater, (d) parametric surface model, and (e) sectioned model of the 3D region of interest

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Fig. 3

(Identical) cutting edge and geometry of the two selected types of turning tool inserts [39]

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Fig. 4

Final machined workpieces used for the turning experiments

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Fig. 10

Plot of specific VTW rate (per minute of stock removal) as a function of increasing MRR for H13A grade inserts (with linear curve fits)

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Fig. 9

Plot of specific VTW rate (per minute of stock removal) as a function of increasing MRR for H10A grade inserts (with linear curve fits)

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Fig. 8

Chatter marks resulting from high feed–low speed process condition on turned Ti–6Al–4V stock

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Fig. 7

Plot of specific VTW as a function of MRR for H13A grade (with second order polynomial fits)

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Fig. 6

Plot of specific VTW as a function of MRR for H10A grade (with second order polynomial fits)

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Fig. 5

VTW of H10A and H13A grade inserts at a feed rate of (a) 0.05 mm/rev, (b) 0.15 mm/rev, and (c) 0.30 mm/rev for different cutting speeds. Note that in (c), the data points for a cutting speed of 120 m/min is not shown due to catastrophic failure of the turning tool inserts.

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Fig. 11

Plot of specific M-ratio (per 10-cm3 of stock removal) against MRR for H10A grade inserts

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Fig. 12

Plot of specific M-ratio (per 10-cm3 of stock removal) against MRR for H13A grade inserts

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