Abstract In general, Physical Vapor Deposition (PVD)-TiN coated High Speed Steel (HSS) endmills used to machine carbon steels can perform better at high cutting speeds compared with uncoated tools resulting in better surface finish and longer tool life. Flank wear is believed to be the main wear type that leads to shorten the life of these cutting tools. In this study, the roles of the coating ...

In a modern machining system, tool condition monitoring systems are needed to get higher quality production and to prevent the downtime of machine tools due to catastrophic tool failures. Also, in precision machining processes surface quality of the manufactured part can be related to the conditions of the cutting tools. This increases industrial interest for in-process tool condition monitorin...

Cutting tool wear is a critical phenomenon which influences the quality of the machined part. In this paper, an attempt has been made to create artificial flank wear using the electrical discharge machining (EDM) process to emulate the actual or real flank wear. The tests were conducted using coated carbide inserts, with and without wear on EN-8 steel, and the acquired data were used to develop...

Machining of carbon fibre reinforced polymer (CFRP) is abrasive and causes significant tool wear. The effect wear on static flexural strength investigated, using edge trimming with uncoated carbide chemical vapour deposition (CVD) diamond coated burr style tools. Edge rounding (ER) criteria along flank are used to observe degradation ER shown preferentially allowing the become cyclically sharpe...

Tool runout, cutting edge radius-size effect, and tool wear have significant impacts on the force of micro-milling. In order to predict micro-milling related performance, it is necessary establish a model including radius, wear. this study, an instantaneous uncut chip thickness (IUCT) considering nonlinear shear/ploughing coefficient cutting-edge friction embedded with flank width are respectiv...

A new prediction method was proposed based on the positive feedback relationship between tool geometry and wear rate. Dry orthogonal cutting of Inconel 718 used as a case study. Firstly, rate models flowchart were proposed. Secondly, evolution during analyzed considering combined effect crater flank wear. Thirdly, temperature, normal stress tool–chip relative sliding velocity surface studied, r...

Strenx 1100 structural steel has unique material properties enables to utilize in important engineering applications such as marine and heavy vehicles. Due the surface integrity of parts produced by this is paramount importance, tool wear condition needs be considered well. As being applicable easy measure, flank (VB) widely preferred field reflects remaining life. Minimum quantity lubrication ...

The challenges of machining, particularly milling, glass fibre-reinforced polymer (GFRP) composites are their abrasiveness (which lead to excessive tool wear) and susceptible to workpiece damage when improper machining parameters are used. It is imperative that the condition of cutting tool being monitored during the machining process of GFRP composites so as to re-compensating the effect of to...

The bandsawing as a multi-point cutting operation is the preferred method for cutting off raw materials in industry. Although cutting off with bandsaw is very old process, research efforts are very limited compared to the other cutting process. Appropriate online tool condition monitoring system is essential for sophisticated and automated machine tools to achieve better tool management. Tool w...