Abstract
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.
Similar content being viewed by others
References
Products—Kennametal Master Cutting Tools; Inc. 525 William Penn Place Suite 330, Pittsburgh. https://www.kennametal.com/pt/pt/products.html, 2020
A. Siddhpura and R. Paurobally, A Review of Flank Wear Prediction Methods for Tool Condition Monitoring in a Turning Process, Int. J. Adv. Manuf. Technol., 2012, 65, p 371–393. https://doi.org/10.1007/s00170-012-4177-1
J. Niu, C. Huang, R. Su, B. Zou, J. Wang, Z. Liu, and C. Li, Study on Surface Integrity of Compacted Graphite Iron Milled by Cemented Carbide Tools and Ceramic Tools, Int. J. Adv. Manuf. Technol., 2019, 103, p 4123–4134. https://doi.org/10.1007/s00170-019-03592-7
R. Su, C. Huang, L. Xu, B. Zou, H. Liu, Y. Liu, and C. Li, Changes of Cutting Performance under Different Workpiece Removal Volume during Normal Speed and High Speed Milling of Compacted Graphite Iron, Int. J. Adv. Manuf. Technol., 2019, 100(9–12), p 2785–2794. https://doi.org/10.1007/s00170-018-2848-2
Y. Guo, T. Stalbaum, J. Mann, H. Yeung, and S. Chandrasekar, Modulation-Assisted High Speed Machining of Compacted Graphite Iron (CGI), J. Manuf. Process, 2013, 15(4), p 426–431. https://doi.org/10.1016/j.jmapro.2013.06.001
M. Chen, L. Jiang, G. Guo, and Q. An, Experimental and FEM Study of Coated and Uncoated Tools Used for Dry Milling of Compacted Graphite Cast Iron, Trans. Tianjin Univ., 2011, 17(4), p 235–241. https://doi.org/10.1007/s12209-011-1609-1
M.P. Kumar, N. Ramakrishna, K. Amarnath, and S.M. Kumar, Study on Tool Life and Its Failure Mechanisms, Int. J. Innov. Res. Sci. Technol., 2015, 2(4), p 126–131
M.C. Perju, D.G. Galuşcă, C. Nejneru, and A.E. Lărgeanu, Ferrite-Pearlite Cast Iron Parts Restoring Using The Impulse Discharge Method, Petrol. Gas Univ. Ploiesti Bull. Tech. Ser., 2010, 62(2), p 97–102
R. Yigit, E. Celik, F. Findik, and S. Koksal, Effect of Cutting Speed on the Performance of Coated and Uncoated Cutting Tools in Turning Nodular Cast Iron, J. Mater. Process Technol., 2008, 204(1), p 80–88. https://doi.org/10.1016/J.Jmatprotec.2007.10.082
Sandivik, https://www.sandvik.coromant.com/en-us/services/pages/recycling.aspx, 2015
W. Grzesik, Advanced Machining Processes of Metallic Materials: Theory, Modelling, and Applications, 2nd ed., 2017
V.V. Oliveira, P.A.C. Beltrão, and G. Pintaude, Effect of Tool Geometry on the Wear of Cemented Carbide Coated with TiAlN during Drilling of Compacted Graphite Iron, Wear, 2010, 271, p 2561–2569. https://doi.org/10.1016/j.wear.2010.12.075
A. Richetti, A.R. Machado, M.B. Silva, E.O. Ezugwu, and J. Bonney, Influence of the Number of Inserts for Tool Life Evaluation in Face Milling of Steels, Int. J. Mach. Tools Manuf., 2004, 44, p 695–700. https://doi.org/10.1016/j.ijmachtools.2004.02.007
J.R.S. Moreno, G.L. Silva, C.E. Silva Junior, and J.F.S. Gonçalves, Comparative Performance Analysis of Tung and Jatropha Emulsions for Development as Cutting Fluids, Mater. Res. Express, 2020, 7, p 1–10. https://doi.org/10.1088/2053-1591/ab5f7e
R.M. Belentani, H. Funes Júnior, F.C. Canarima, A.E. Dinizb, A. Hassuib, P.R. Aguiarc, and E.C. Bianchi, Utilization of Minimum Quantity Lubrication (MQL) with Water in CBN Grinding of Steel, Mater. Res., 2014, 17(1), p 88–96. https://doi.org/10.1590/s1516-14392013005000165
C.A.S. Bork, J.F.S. Gonçalves, J.O. Gomes, and J. Gheller, Performance of the Jatropha Vegetable-Base Soluble Cutting Oil as a Renewable Source in the Aluminum Alloy 7050-T7451 Milling, J. Manuf. Sci. Technol., 2014, 7, p 210–221. https://doi.org/10.1016/j.cirpj.2014.04.004
S. Kedare, D. Borse, and P. Shahane, Effect of Minimum Quantity Lubrication (MQL) on Surface Roughness of Mild Steel of 15 HRC on Universal Milling Machine, Procedia Mater. Sci., 2015, 6, p 150–153. https://doi.org/10.1016/j.mspro.2014.07.018
B.L. Tai, D.A. Stephenson, R.J. Furness, and A.J. Shih, Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining, Procedia CIRP, 2014, 14, p 523–528. https://doi.org/10.1016/j.procir.2014.03.044
X. Youqiang, D. Jianxin, Z. Kedong, W. Xingsheng, L. Yunsong, and Z. Yonghui, Fabrication and Dry Cutting Performance of Si3N4/TiC Ceramic Tools Reinforced with the PVD WS2/Zr Soft-Coatings, Ceram. Int., 2015, 41, p 10261–11027. https://doi.org/10.1016/j.ceramint.2015.04.153
A.M. Souza, W.F. Sales, S.C. Santos, and A.R. Machado, Performance of Single Si3N4 and Mixed Si3N4/CPCBN Wiper Cutting Tools Applied to High Speed Face Milling of Cast Iron, Int. J. Mach. Tools Manuf., 2005, 45, p 335–344. https://doi.org/10.1016/j.ijmachtools.2004.08.006
W. Grzesik, J. Rech, and Z. Żak, Determination of Friction in Metal Cutting with Tool Wear and Flank Face Effects, Wear, 2014, 317, p 8–16. https://doi.org/10.1016/j.wear.2014.05.003
A. Siddhpura and R. Pauro, A Study of the Effects of Friction on Flank Wear and the Role of Friction in Tool Wear Monitoring, Aust. J. Mech. Eng., 2011, 10(2), p 141–156. https://doi.org/10.7158/M12-027.2012.10.2
F. Zemzemi, J. Rech, W. Ben Salem, A. Dogui, and P. Kapsa, Identification of a Friction Model at Tool/Chip/Workpiece Interfaces in Dry Machining of AISI4142 Treated Steels, J. Mater. Process. Technol., 2009, 209(8), p 3978–3990. https://doi.org/10.1016/j.jmatprotec.2008.09.019
R. Suresh and S. Basavarajappa, Effect of Process Parameters on Tool Wear and Surface Roughness during Turning of Hardened Steel with Coated Ceramic Tool, Procedia Mater. Sci., 2014, 5, p 1450–1459. https://doi.org/10.1016/j.mspro.2014.07.464
Y.C. Yen, A. Jain, and T. Altan, A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries, J. Mater. Process. Technol., 2004, 146(1), p 72–81. https://doi.org/10.1016/S0924-0136(03)00846-X
V. Nayyar, J. Kaminski, A. Kinnander, and L. Nyborg, An Experimental Investigation of Machinability of Graphitic Cast Iron Grades; Flake, Compacted and Spheroidal Graphite Iron in Continuous Machining Operations, Procedia CIRP, 2012, 1, p 488–493. https://doi.org/10.1016/j.procir.2012.04.087
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Moreno, J.R.S., Ribeiro, A.A. & de Souza Gonçalves, J.F. 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. J. of Materi Eng and Perform 30, 248–257 (2021). https://doi.org/10.1007/s11665-020-05319-2
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-020-05319-2