V.F. Ruisi

Wear mechanism of ceramic tools

Abstract Cutting tests were performed using ceramic cutting tools under continuous cutting conditions. The tests were carried out on AISI 1040 steel, with cutting speeds ranging from 5 to 11 m s −1 . The wear mechanism was investigated for both crater and flank. Alumina-toughened zirconia of submicron grain size showed the best wear resistance. Alumina with TiC, TiN and ZrO 2 inclusions exhibited a wear resistance a little lower than the above-mentioned materials. Low chemical stability seems to be the reason for the poor performances of the silicon carbide whiskers-reinforced alumina, silicon nitride and the tungsten carbide inserts.

Surface roughness detection by tool image processing

Abstract A new technique for the on-line control of the surface roughness in the finish turning operation is presented. By means of tool image detection and processing, the ideal roughness profile that the tool should produce on the workpiece is evaluated. A model to estimate the value of the effective roughness of the workpiece from one related to the ideal profile is proposed. This model is not significantly influenced by the feed employed.

Ceramic materials wear mechanisms when cutting nickel-based alloys

Abstract In this paper the performances of some commercial ceramic inserts when cutting AISI 310 steel are investigated and compared to those of a traditional carbide based tool. The most important wear mechanism in the ceramic inserts is related to the segmented edges of the chips that abrade a notch at the end of the cut zone. Alumina–zirconia inserts are very sensitive to this kind of wear, whereas tools made of Sialon and alumina with SiC whiskers exhibit slightly better performances despite the concomitant chemical wear mechanisms.

Cutting Temperatures Evaluation in Ceramic Tools: Experimental Tests, Numerical Analysis and SEM Observations

The authors propose a multiple approach for the evaluation of cutting temperatures in ceramic tools. The first approach was the experimental evaluation of equitemperature lines, obtained in three-dimensional cutting by employing constant melting point powders scattered on planes parallel to rake face. In the second approach, a numerical finite element analysis was performed. At this step the determination of the percentage of total heat produced in the operation that flows into the tool was considered and, consequently, the temperature distribution within the whole volume of the insert. Finally, the examination of the crater zone with SEM microscopy confirmed the temperature levels as previous estimated.

Wear performance of ceramic cutting tool materials when cutting steel

Abstract Some test cycles have been carried out in continuous cutting conditions, employing cutting parameters (feed, depth of cut and cutting speed) chosen following experimental planes and suitable test fields. The wear tests have been carried out on AISI 1040 steel with cutting speeds from 5m/sec to 11m/sec. The silicon nitride, sintered carbide, cubic boron nitride and alumina reinforced with SiC whiskers inserts, have shown, at each assigned cutting parameter, poor wear resistance when cutting steel. Alumina and alumina in submicron grain, which has been toughened by ZrO2 phase transformation, and the oxide-based alumina, have been the better wear resistance. The mixed based alumina has shown a wear resistance, a little lower than the previous materials. The low chemical stability seems to be the reason for the poor performances of the silicon nitride and the silicon carbide whiskers reinforced alumina inserts. The high wear rate of the sintered carbide and the cubic boron nitride is essentially due to the pull out of the ceramic particles. From the other hand, the chemical stability, together with their good mechanical properties can explain the appreciable results obtained with the other alumina based materials.

Study of new joining technique: flat clinching

In this paper a development of clinching, called flat clinching, is presented. After a press clinching process, the joined sheets have been deformed by a punch with a lower diameter against a flat die. In this way a new configuration is created with a geometry that has no discontinuity on the external surface (bottom). A new procedure has also been tested: the second step is perfomed by pressing the joint between two flat dies. This second case has revealed itself to be very effective.Tensile tests have been done to compare the joints strength among the various joining techniques. Moreover some joints have been cut to analyse the changing of the contact line shape and how its characteristics parameters can influence the bonding performances. To optimise the process a finite element analysis has been performed.

A new on-line roughness control in finish turning operation

A new on-line control method for the wear state of sintered carbide tools for finish turning operations is proposed.

Computer vision profilometer: equipment and evaluation of measurements

Abstract This paper describes a new equipment that measures roughness values by a computer vision (CV) technique. Measurements carried out by a CV profilometer are also evaluated. A laser source (power 2 mW), a cylindrical lens and a charge coupled device (CCD) TV-camera with a suitable optical system form an image of the profile of the sample under inspection. This image is then transformed into a binary image by thresholding and the line that divides the bright zone from the dark zone is the sample profile. From this line the characteristic roughness values can be calculated. The roughness measurements are carried out both by the CV profilometer and a stylus profilometer on eight specimens with various degrees of finish. For each investigated parameter, a strong linear relationship exists between CV and stylus measurements.

Effect of Chemical Etching on Adhesively Bonded Aluminum AA6082

The efforts of new automotive industry are mainly directed towards the substitution of aluminum for steel in the body structure because the aluminum structures are lighter than traditional steel ones and meet the requirements, in terms of both vehicle design and manufacture. However, this substitution is not so automatic, but it is important to study the material properties and the structure design, focusing the attention on the methods of joining. Welding, typical technique to joint steel parts, is particularly difficult when applied on aluminum ones and then, in many cases, the adhesive bonding is preferred. To optimise the joint performances it is necessary to pre-treat the metal surface, not only to remove contaminants, but also to provide the intimate contact needed for the adhesive to successfully bond with the adherent surface. The mere cleaning of aluminum surfaces is not suitable for their bonding due to the oxide layer that naturally occurs on exposure to air so we need to apply a more effective treatment (mechanical or chemical etching) to increase the adhesion capability of the substrates. In this work different adhesive joint configurations (single lap) between aluminum substrates are studied. Two different resins are employed to evaluate the influence of the adhesive on the joint performances. Moreover the aluminum sheets are treated with a chemical etching with two different procedures.

Minor Cutting Edge Wear in Finish Turning Operations

In finish turning operation, it has already shown, that for the sake of control the dimensional accuracy and the micro-geometry of the worked surface, the wear parameters employed in rough turning operations are not suitable. In the present work the study of wear in fmish turning operations, is carried out, employing a particular groove survey methodology, already proposed in a previous paper, that is based on the techniques of acquirement and processing of images. In order to verify the applicability of the proposed technique two kind of alumina-based inserts and two kind of sintered carbide inserts have been tested. The experimental tests have confirmed the validity of the technique in the prediction of tool lifetimes for several couples toolworkpiece materials.