Conference Papers

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    A pressured steam JET approach to tool wear minimization in cutting of metal matrix composites
    (Trans Tech Publications Ltd, 2007) Anjaiah, D.; Shetty, R.; Pai B, R.; Vijaya, M.V.; Rao, S.S.
    Metal matrix composites (MMCs) have been found to possess tremendous prospective engineering applications that require materials offering a combination of lightweight with considerably enhanced mechanical and physical properties. However, the applications of MMCs are limited by their poor machinability which is a result of their highly abrasive nature that causes excessive wear to the cutting tools. In this study, an investigation into the mechanism of the tool wear in cutting of MMCs is carried out. It is found that during cutting of an MMC, the tool cutting edge will impact on the reinforcement particles. The impacted particles will then either be dislodged from the matrix, doing no harm to the tool, or be embedded into the matrix, ploughing on the tool flank and causing excessive tool flank wear. According to this tool wear mechanism, a pressured steam jet approach is developed for the minimization of the tool wear by preventing the impacted reinforcement particles from being embedded in the workpiece matrix. Experimental tests for cutting of SiC-aluminum MMC using cubic boron nitride (KB-90) and polycrystalline diamond (KP-300) tool inserts with the aid of the pressured steam jet are conducted. The results show that from full factorial design of experiments the effect of the pressured steam jet plays a significant role on the tool wear followed by tool inserts and depth of cut. The working mechanism of the pressured steam jet method and the experimental testing results are discussed in detail.
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    Influence of modified cutting inserts in machining of Ti-6Al-4V alloy using PCD insert
    (Elsevier Ltd, 2018) Rao, R.; Rao, S.S.; Herbert, M.A.
    In modern manufacturing industries, the emerging needs of modern metal cutting operation are to increase the tool life with good surface finish and higher material removal rate. These objectives can be achieved by reducing the cutting temperature at the cutting zones with proper cooling system. The present work involves the experimental study of MQL application through the micro-holes drilled on the cutting inserts during turning of Ti-6Al-4V alloy using PCD inserts. The effect of the micropool lubrication of cutting insert on cutting temperature, surface roughness and tool wear have been compared with normal insert machining. It has been observed that in micropool lubrication method, cutting temperature was reduced by 30-33% over normal insert machining. Micropool lubrication reduced the flank wear to a maximum of about 20-30% over normal insert machining. The experimental result of the current research work indicates considerable benefits of surface roughness and tool wear through reduction in cutting temperature due to the perforation of the cutting insert. © 2018 Elsevier Ltd. All rights reserved.