This document discusses the machinability of three aluminum alloys - GIANTAL, WELDURAL, and HOKOTOL - that have been specially developed for mold and tool construction. It examines their machinability when subjected to various machining processes like milling and summarizes the resulting surface roughness and chip shapes achieved under different cutting conditions and cooling methods. The document contains detailed tables reporting the tool parameters used and measurement results for each alloy and machining scenario.
Turning plays most important role in Machining and Turning is the form of machining process which uses a single-point cutting tool for material removal,from this slide we can get the importance of turning.
This document provides information on planing machines and their components. It discusses different types of planer knives and the factors to consider when selecting knives, such as the material being processed. It describes various knife materials like chrome vanadium steel, high speed steel, and tungsten carbide. The document outlines knife geometry specifications, including rake angle, bevel angle, clearance angle, and peripheral cutting speed. It also addresses pitch distance, chip formation, riving, cutter projection, and maintenance of planing machines.
This document provides information about machine anatomy and construction, specifically regarding surface planers, thicknessers, and rip/panel saws. It discusses the parts, design, functions, processes, safety, use, and maintenance of these machines. The sections cover topics like cutter block design, knife geometry, chip formation, risk assessment, and blade configurations. The goal is to educate students about the components and operation of various woodworking machinery.
This document discusses emerging cutting tool materials that can improve machining performance. It begins by explaining that machining involves cutting tools undergoing high forces and temperatures, so tool life and geometry are important considerations. Different tool materials are then outlined, including tungsten carbide, high-speed steel, ceramics, cermets, cubic boron nitride, polycrystalline diamond, and diamond coatings. Each material has advantages like high hardness, toughness, wear resistance, or thermal conductivity suited for different machining applications. The document concludes that continuous development of new tool materials and treatments can further push the limits of cutting performance.
The document summarizes key aspects of cutting tool technology. It discusses the three main modes of tool failure and how gradual wear is preferred. Tool materials are described, including high speed steel, cemented carbides, cermets, ceramics, and coatings. Tool geometry, including elements for single-point and multi-point tools, is covered. Functions of cutting fluids in reducing heat and friction are explained.
This document provides an overview of cutting tools and cutting fluids. It begins by defining the objectives of understanding cutting tool nomenclature, materials, and applications. It then describes different types of cutting tools, such as high-speed steel, cemented carbides, ceramics, and diamond toolbits. It also discusses cutting fluid types like oils, emulsifiable oils, and chemical fluids, and their functions in cooling, lubricating, and prolonging tool life during machining operations.
Studies on Tool Life and Cutting Forces for Drilling Operation using Uncoated...IRJET Journal
This document summarizes a study that compares the tool life and cutting forces of uncoated and coated high-speed steel (HSS) drill bits during dry drilling of EN8 steel. Specifically, it examines uncoated HSS drill bits, as well as HSS drill bits coated with titanium nitride (TiN) and titanium aluminium nitride (TiAlN). Experimental results showed that the TiAlN coated HSS drill bit had the greatest tool life. When measuring cutting forces, the TiAlN coated drill bit produced the highest thrust force, while torque was similar across all drill bits. In conclusion, coatings like TiN and TiAlN can improve the performance of HSS drill bits during machining operations
Chronological developments in Cutting Tool MaterialsBilal Syed
This is ap resentation showing the developments of cutting tools materials used from early life to present. their materials, properties, advantages, etc.
Turning plays most important role in Machining and Turning is the form of machining process which uses a single-point cutting tool for material removal,from this slide we can get the importance of turning.
This document provides information on planing machines and their components. It discusses different types of planer knives and the factors to consider when selecting knives, such as the material being processed. It describes various knife materials like chrome vanadium steel, high speed steel, and tungsten carbide. The document outlines knife geometry specifications, including rake angle, bevel angle, clearance angle, and peripheral cutting speed. It also addresses pitch distance, chip formation, riving, cutter projection, and maintenance of planing machines.
This document provides information about machine anatomy and construction, specifically regarding surface planers, thicknessers, and rip/panel saws. It discusses the parts, design, functions, processes, safety, use, and maintenance of these machines. The sections cover topics like cutter block design, knife geometry, chip formation, risk assessment, and blade configurations. The goal is to educate students about the components and operation of various woodworking machinery.
This document discusses emerging cutting tool materials that can improve machining performance. It begins by explaining that machining involves cutting tools undergoing high forces and temperatures, so tool life and geometry are important considerations. Different tool materials are then outlined, including tungsten carbide, high-speed steel, ceramics, cermets, cubic boron nitride, polycrystalline diamond, and diamond coatings. Each material has advantages like high hardness, toughness, wear resistance, or thermal conductivity suited for different machining applications. The document concludes that continuous development of new tool materials and treatments can further push the limits of cutting performance.
The document summarizes key aspects of cutting tool technology. It discusses the three main modes of tool failure and how gradual wear is preferred. Tool materials are described, including high speed steel, cemented carbides, cermets, ceramics, and coatings. Tool geometry, including elements for single-point and multi-point tools, is covered. Functions of cutting fluids in reducing heat and friction are explained.
This document provides an overview of cutting tools and cutting fluids. It begins by defining the objectives of understanding cutting tool nomenclature, materials, and applications. It then describes different types of cutting tools, such as high-speed steel, cemented carbides, ceramics, and diamond toolbits. It also discusses cutting fluid types like oils, emulsifiable oils, and chemical fluids, and their functions in cooling, lubricating, and prolonging tool life during machining operations.
Studies on Tool Life and Cutting Forces for Drilling Operation using Uncoated...IRJET Journal
This document summarizes a study that compares the tool life and cutting forces of uncoated and coated high-speed steel (HSS) drill bits during dry drilling of EN8 steel. Specifically, it examines uncoated HSS drill bits, as well as HSS drill bits coated with titanium nitride (TiN) and titanium aluminium nitride (TiAlN). Experimental results showed that the TiAlN coated HSS drill bit had the greatest tool life. When measuring cutting forces, the TiAlN coated drill bit produced the highest thrust force, while torque was similar across all drill bits. In conclusion, coatings like TiN and TiAlN can improve the performance of HSS drill bits during machining operations
Chronological developments in Cutting Tool MaterialsBilal Syed
This is ap resentation showing the developments of cutting tools materials used from early life to present. their materials, properties, advantages, etc.
Investigations on Milling Tool: - A Literature ReviewIJRES Journal
Milling machines are tools designed to machine metal, wood, and other solid materials. Often automated, milling machines can be positioned in either vertical or horizontal orientation to carve out materials based on a pre-existing design. The main aim of this paper is to focus on the study of effects of cutting tools on various materials while the parameters are kept constant and also by varying the parameters. A literature review was conducted to find the effects of different cutting tools on milling of different materials. It was found out that most of the work was done using single tool and single material and results were recorded. The literature review gives us idea to use more than one material and subject it to the single tool. And then a comparison can be made on the results that are recorded.
The document reviews the analysis and optimization of cylindrical grinding process parameters on the material removal rate of EN15AM steel. It discusses how grinding wheel speed, workpiece speed, feed rate, depth of cut, and cutting fluid impact the material removal rate. The optimized parameters identified were a grinding wheel speed of 1800 rpm, workpiece speed of 155 rpm, feed rate of 275 mm/min, and depth of cut of 0.04 mm.
Абразивные материалы для металлообрабатывающей промышленностиdedvandal
The document discusses different abrasive materials for metalworking including Cubitron, Trizact, and Scotch-Brite. Cubitron features mineral crystals that maintain sharp cutting edges. Trizact uses microstructured pyramid patterns to continuously expose fresh cutting surfaces. Scotch-Brite is suitable for finishing surfaces. The document provides information on selecting the appropriate abrasive material and grain size for different metalworking applications and desired surface finishes.
This document provides an overview of drilling, reaming and grinding processes. It describes how drilling uses a rotating multi-point drill bit to cut circular holes. Reaming enlarges and finishes previously drilled holes to tight tolerances. Grinding uses an abrasive wheel to remove small amounts of material from a workpiece. The document discusses various drill bits and reamer types, factors that influence accuracy and surface finish, and considerations for production economics with each process.
The document discusses various product design techniques for manufacturing, including cutting by abrasion where an abrasive material is used to shape a workpiece through rubbing, and the mechanics of abrasion which involve grains of abrasive material contacting and removing fragments of the workpiece. It also describes factors that affect abrasion such as hardness, grain size, force, and lubricants. Specific techniques covered include grinding, polishing, buffing, flame cutting which uses an oxygen jet to cut materials, and laser cutting which uses a concentrated beam of light to precisely cut thin materials. Water jet cutting is also summarized, which uses a high pressure water jet optionally with abrasive particles to cut materials without thermal effects.
Dia casting and its types by alpha metal industriesroshnipatel829
Dia Casting And Its Types discusses the two main types of casting processes: expendable and nonexpendable mold casting. It focuses on die casting, describing the types of die casting machines and processes like gravity die casting. The document outlines materials commonly used for die casting such as aluminum, zinc, magnesium, and copper. It provides specifications for minimum thicknesses and draft angles when die casting different materials. In closing, it summarizes advantages like dimensional accuracy and rapid production, and disadvantages which include limitations on part size and need for high production volumes.
Hakansson Saws India Pvt. Ltd. was established in the year 2009 as a private limited organization and is engaged in manufacturing and supplying a comprehensive range of Bandsaw Machines & Bandsaw Blades. Products comprise in these categories are Aluminium Runner & Riser Cutting Machines, Automatic Bandsaw Machines, Semi Automatic Bandsaw Machines & Bimetal Bandsaw Blades.
Analysis of machining parameters using MQL conditionPadmalochan Nanda
The document discusses an analysis of machining parameters in turning operations using minimum quantity lubrication (MQL). MQL uses much less cutting fluid compared to conventional flooding lubrication. The study aims to measure surface roughness, tool wear, and cutting temperature under dry, flooded, and MQL conditions. Various machining parameters like cutting velocity, feed rate, and depth of cut are investigated. Preliminary results found that MQL reduced average cutting temperature by 5-10% compared to dry and flooded conditions. MQL also showed lower tool wear and better surface finish outcomes than dry machining. The results suggest MQL can improve machining performance over conventional flooded lubrication.
The document discusses tool wear, types of tool wear including flank wear, crater wear and nose wear. It describes how tool wear occurs and the factors affecting tool wear and tool life. These factors include cutting speed, feed rate, depth of cut, tool geometry, tool and work material, cutting fluids, and rigidity of machine tool. The document also discusses machinability, factors affecting machinability, evaluation of machinability, and measurement of surface roughness.
This document discusses various machining operations used for manufacturing metal and plastic parts. It begins by defining machining as a process that cuts raw materials into desired shapes and sizes through controlled material removal. The main machining operations described are turning, milling, and drilling. It also discusses machining stages, cutting conditions, machining plastic versus metal, and plastic-specific processes like polishing, annealing, and different categories of plastics to machine.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
Please refer this file just as reference material. More concentration should on class room work and text book methodology.
Thermal aspects of Machining, Tool materials, Tool wear Cutting fluids and Machinability.
This document discusses machining technology and metal cutting processes. It covers the following key points:
1) Machining is a finishing process used to impart dimensional accuracy, form, and surface finish to enable products to fulfill functional requirements and provide long service life.
2) The form of chips produced during machining indicates the nature of material removal and interactions at the chip-tool interface, and depends on work material, tool geometry, cutting parameters, and environment.
3) Cutting tools are either single-point or multi-point, and cutting processes can be orthogonal or oblique. Mechanisms of chip formation differ for ductile vs. brittle materials.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
This document discusses abrasive jet machining (AJM), including its objectives, construction, working principle, applications, advantages, and disadvantages. AJM works by using compressed gas to propel abrasive particles at high velocity towards a workpiece, eroding material. It can machine heat-sensitive, brittle, thin, or hard materials. The key components are a compressor, mixing chamber, nozzle, and exhaust. Applications include cutting, drilling, boring, trimming, and surface finishing. Advantages include the ability to machine heat-sensitive materials and reach inaccessible areas, while producing a high surface finish, with low heat and cost. Disadvantages include a low material removal rate and inability to reuse abrasive particles.
The document discusses theories of metal machining and chip formation. It describes how early theories like the theory of tear and theory of compression were later disproven. The generally accepted theory today is the theory of shear, which proposes that metal cutting occurs through shear along a plane at an angle to the cutting direction. The document also outlines the difficulties in studying metal cutting processes and how orthogonal cutting experiments were developed to simplify the analysis.
design n testing of tool used in press shopParag Kapile
The document summarizes a project analyzing punch tools used in sheet metal industries. It models various punch profiles, including flat, convex, concave, and one-way shear, using finite element analysis to minimize stress on the tool. Analysis found radial deformation and stresses were lowest for punches with a 22.5 degree balanced convex shear. It recommends this punch type to reduce stress and enable using lower press capacities. The project aims to increase tool life by optimizing punch cutting profiles through finite element modeling.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
The document summarizes the JINGDIAO GRA200 5-axis graphite mill machining center. It has a 500/280/300mm travel with -120 to 90 degree B-axis and 360 degree C-axis rotation. It is designed for high-precision graphite electrode machining down to 0.1um feeds and 1um accuracy. The document provides details on its machine design, dust collection system, optional spindles, tooling, CNC control, and inspection capabilities.
Investigations on Milling Tool: - A Literature ReviewIJRES Journal
Milling machines are tools designed to machine metal, wood, and other solid materials. Often automated, milling machines can be positioned in either vertical or horizontal orientation to carve out materials based on a pre-existing design. The main aim of this paper is to focus on the study of effects of cutting tools on various materials while the parameters are kept constant and also by varying the parameters. A literature review was conducted to find the effects of different cutting tools on milling of different materials. It was found out that most of the work was done using single tool and single material and results were recorded. The literature review gives us idea to use more than one material and subject it to the single tool. And then a comparison can be made on the results that are recorded.
The document reviews the analysis and optimization of cylindrical grinding process parameters on the material removal rate of EN15AM steel. It discusses how grinding wheel speed, workpiece speed, feed rate, depth of cut, and cutting fluid impact the material removal rate. The optimized parameters identified were a grinding wheel speed of 1800 rpm, workpiece speed of 155 rpm, feed rate of 275 mm/min, and depth of cut of 0.04 mm.
Абразивные материалы для металлообрабатывающей промышленностиdedvandal
The document discusses different abrasive materials for metalworking including Cubitron, Trizact, and Scotch-Brite. Cubitron features mineral crystals that maintain sharp cutting edges. Trizact uses microstructured pyramid patterns to continuously expose fresh cutting surfaces. Scotch-Brite is suitable for finishing surfaces. The document provides information on selecting the appropriate abrasive material and grain size for different metalworking applications and desired surface finishes.
This document provides an overview of drilling, reaming and grinding processes. It describes how drilling uses a rotating multi-point drill bit to cut circular holes. Reaming enlarges and finishes previously drilled holes to tight tolerances. Grinding uses an abrasive wheel to remove small amounts of material from a workpiece. The document discusses various drill bits and reamer types, factors that influence accuracy and surface finish, and considerations for production economics with each process.
The document discusses various product design techniques for manufacturing, including cutting by abrasion where an abrasive material is used to shape a workpiece through rubbing, and the mechanics of abrasion which involve grains of abrasive material contacting and removing fragments of the workpiece. It also describes factors that affect abrasion such as hardness, grain size, force, and lubricants. Specific techniques covered include grinding, polishing, buffing, flame cutting which uses an oxygen jet to cut materials, and laser cutting which uses a concentrated beam of light to precisely cut thin materials. Water jet cutting is also summarized, which uses a high pressure water jet optionally with abrasive particles to cut materials without thermal effects.
Dia casting and its types by alpha metal industriesroshnipatel829
Dia Casting And Its Types discusses the two main types of casting processes: expendable and nonexpendable mold casting. It focuses on die casting, describing the types of die casting machines and processes like gravity die casting. The document outlines materials commonly used for die casting such as aluminum, zinc, magnesium, and copper. It provides specifications for minimum thicknesses and draft angles when die casting different materials. In closing, it summarizes advantages like dimensional accuracy and rapid production, and disadvantages which include limitations on part size and need for high production volumes.
Hakansson Saws India Pvt. Ltd. was established in the year 2009 as a private limited organization and is engaged in manufacturing and supplying a comprehensive range of Bandsaw Machines & Bandsaw Blades. Products comprise in these categories are Aluminium Runner & Riser Cutting Machines, Automatic Bandsaw Machines, Semi Automatic Bandsaw Machines & Bimetal Bandsaw Blades.
Analysis of machining parameters using MQL conditionPadmalochan Nanda
The document discusses an analysis of machining parameters in turning operations using minimum quantity lubrication (MQL). MQL uses much less cutting fluid compared to conventional flooding lubrication. The study aims to measure surface roughness, tool wear, and cutting temperature under dry, flooded, and MQL conditions. Various machining parameters like cutting velocity, feed rate, and depth of cut are investigated. Preliminary results found that MQL reduced average cutting temperature by 5-10% compared to dry and flooded conditions. MQL also showed lower tool wear and better surface finish outcomes than dry machining. The results suggest MQL can improve machining performance over conventional flooded lubrication.
The document discusses tool wear, types of tool wear including flank wear, crater wear and nose wear. It describes how tool wear occurs and the factors affecting tool wear and tool life. These factors include cutting speed, feed rate, depth of cut, tool geometry, tool and work material, cutting fluids, and rigidity of machine tool. The document also discusses machinability, factors affecting machinability, evaluation of machinability, and measurement of surface roughness.
This document discusses various machining operations used for manufacturing metal and plastic parts. It begins by defining machining as a process that cuts raw materials into desired shapes and sizes through controlled material removal. The main machining operations described are turning, milling, and drilling. It also discusses machining stages, cutting conditions, machining plastic versus metal, and plastic-specific processes like polishing, annealing, and different categories of plastics to machine.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
Please refer this file just as reference material. More concentration should on class room work and text book methodology.
Thermal aspects of Machining, Tool materials, Tool wear Cutting fluids and Machinability.
This document discusses machining technology and metal cutting processes. It covers the following key points:
1) Machining is a finishing process used to impart dimensional accuracy, form, and surface finish to enable products to fulfill functional requirements and provide long service life.
2) The form of chips produced during machining indicates the nature of material removal and interactions at the chip-tool interface, and depends on work material, tool geometry, cutting parameters, and environment.
3) Cutting tools are either single-point or multi-point, and cutting processes can be orthogonal or oblique. Mechanisms of chip formation differ for ductile vs. brittle materials.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
This document discusses abrasive jet machining (AJM), including its objectives, construction, working principle, applications, advantages, and disadvantages. AJM works by using compressed gas to propel abrasive particles at high velocity towards a workpiece, eroding material. It can machine heat-sensitive, brittle, thin, or hard materials. The key components are a compressor, mixing chamber, nozzle, and exhaust. Applications include cutting, drilling, boring, trimming, and surface finishing. Advantages include the ability to machine heat-sensitive materials and reach inaccessible areas, while producing a high surface finish, with low heat and cost. Disadvantages include a low material removal rate and inability to reuse abrasive particles.
The document discusses theories of metal machining and chip formation. It describes how early theories like the theory of tear and theory of compression were later disproven. The generally accepted theory today is the theory of shear, which proposes that metal cutting occurs through shear along a plane at an angle to the cutting direction. The document also outlines the difficulties in studying metal cutting processes and how orthogonal cutting experiments were developed to simplify the analysis.
design n testing of tool used in press shopParag Kapile
The document summarizes a project analyzing punch tools used in sheet metal industries. It models various punch profiles, including flat, convex, concave, and one-way shear, using finite element analysis to minimize stress on the tool. Analysis found radial deformation and stresses were lowest for punches with a 22.5 degree balanced convex shear. It recommends this punch type to reduce stress and enable using lower press capacities. The project aims to increase tool life by optimizing punch cutting profiles through finite element modeling.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
The document summarizes the JINGDIAO GRA200 5-axis graphite mill machining center. It has a 500/280/300mm travel with -120 to 90 degree B-axis and 360 degree C-axis rotation. It is designed for high-precision graphite electrode machining down to 0.1um feeds and 1um accuracy. The document provides details on its machine design, dust collection system, optional spindles, tooling, CNC control, and inspection capabilities.
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
This document discusses optimizing cutting parameters for high speed turning of Inconel 625 super alloy using the Taguchi technique. Inconel 625 is difficult to machine due to its properties. The study aims to determine optimal cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate. Experiments are conducted on a CNC turning machine using tungsten carbide tools and Taguchi's L9 orthogonal array. The cutting forces and responses of surface roughness and material removal rate are measured. Regression and Taguchi design of experiments methods are used for analysis to determine the optimal cutting parameters for high speed machining of Inconel 625 super alloy.
Experimental Analysis of Machining Parameters on Turning with Single Point Cu...ijtsrd
This document summarizes an experimental analysis of machining parameters when using a single point cutting tool in turning operations. The experiment tested various spindle speeds, feed rates, and depths of cut to determine their effects on surface roughness, tool life, and material removal rate (MRR). Tests were conducted on a lathe using a high-speed steel single point tool to machine S50C medium carbon steel. Results showed that higher speeds, feeds, and depths increased MRR but decreased tool life. Surface roughness also increased at higher speeds. The analysis provides equations to calculate cutting forces, tool life, surface roughness, and MRR based on the machining parameters. Graphs of the results are also presented. In conclusion, the optimal mach
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
Investigation of turning process to improve productivity mrr for better sur...IAEME Publication
This document summarizes a study that investigated turning parameters to improve productivity (material removal rate or MRR) while achieving better surface finish when machining an aluminum alloy (Al-7075-T6). Taguchi methodology was used to optimize cutting speed, feed rate, and depth of cut. The analysis found that feed rate most significantly influenced surface roughness, while cutting speed most significantly affected MRR. The optimal parameters for high MRR with good surface finish were determined to be a cutting speed of 15.102 m/min, feed rate of 0.3207 mm/rev, and depth of cut of 0.5 mm.
The intention of this report is to briefly, explain some of the machining operations that are involved in the process of TURNING, these are: Cutting Speed, Depth of Cut, Feed Rate and Spindle Speed.
Also demonstrated will be the mathematical calculations involved in the same process, using various equations.
The document describes a GRA400 5-axis high-speed machining center capable of precision machining of dies, molds, and complex hardware parts. It has fully closed-loop control for 5-axis machining and can achieve machining effects of 0.1 μm feed, 1 μm cutting, and nanoscale roughness stability. It also has a strong load capacity direct drive double axis rotary table with high machining accuracy.
The GRA300 is a 5-axis high-speed machining center designed for precision machining of dies, molds, and complex hardware parts. It has fully closed-loop control for stable 5-axis machining and a maximum workpiece dimension of 390x510x300mm. Optional accessories include various tool magazines and an MHS60 material handling system to enable continuous, unattended production.
Cutting Parameters Optimization in Milling Of P – 20 Tool Steel And EN31B IOSR Journals
The objective of the paper is to obtain an optimal setting of CNC machining process parameters,
cutting speed, feed rate resulting in optimal values of the feed and radial forces while machining P – 20 tool
steel and EN31B with TiN coated tungsten carbide inserts. The effects of the selected process parameters on the
chosen characteristics and the subsequent optimal settings of the parameters have been accomplished using
Taguchi’s parameter design approach.The process parameters considered are – Cutting speed 3000rpm,
2500rpm and 2000rpm. Feed rate 200mm/min, 300mm/min and 400mm/min and depth of cut is 0.2mm.The
effect of these parameters on the feed force, radial force are considered for analysis.The analysis of the results
shows that the optimal settings for low values of feed and radial forces are high cutting speed, low feed rate and
depth of cut.The thrust force and feed force are also taken experimentally using dynamometer for above Cutting
speeds, feed rate and depth of cut. The optimal values for speed, feed rate and depth of cut are taken using
Taguchi technique.Taguchi methods are statistical methods developed by Genichi Taguchi to improve the
quality of manufactured goods, and more recently also applied to, engineering, biotechnology, marketing and
advertising.Process used in this project is milling process. Machine selected is Vertical milling center. Machine
model selected is BFW Agni 45. Modeling is done in Pro/Engineer and analysis is done in ANSYS.
PARAMETRIC STUDY OF THE EFFECT OF MACHINING PARAMETERS IN DRILLING USING TAGU...AM Publications
An attempt has been made into the role of conducting an experimental research on aluminium alloys by using the technique to find and correlate Taguchi technological factors for the economy of the machining process. The powerful statistical tool Taguchi method is a systematic application of design and analysis of experiments. It is an effective way to produce high quality at a relatively low cost method. Improving one parameter leads to degradation of other parameters and optimization of various parameters is much more complicated. Therefore, Taguchi technique is used to investigate the characteristic multiple performance in drilling operation. In this paper, the effect of the variation of machining parameters such as speed, power, depth of cut and radius nose in Al6063T6 has been studied and presented. First, the optimal arrangement of the four parameters of rotation has been determined using the configuration of the Taguchi L9 technique with a variation in three levels. After machining is completed, the values are documented and compared using statistical analysis software.
DETERMINING THE INFLUENCE OF CUTTING FLUID ON SURFACE ROUGHNESS DURING MACHIN...Journal For Research
Evaluation of the performance of cutting fluid in machining different work materials in order to improve the efficiency of any machining process. The efficiency can be evaluated based on certain process parameters such as flank wear, surface roughness on the work piece, cutting force developed, temperature developed at the tool-chip interface, etc. The main aim of the project is to determine the influence of cutting fluids in metal working. Servo 68 is mainly used for investigation based on surface roughness during milling of EN24 and EN8 steel with carbide tool. Three square pieces of EN 24 material and three round pieces of EN8 material are taken for machining. Different cutting parameters are considered for feed rate, speed and depth of cut. the six pieces are machined with different parameters and surface roughness values are investigated experimentally.
IRJET- Determining the Effect of Cutting Parameters in CNC TurningIRJET Journal
This document discusses a study that aims to determine the effect of cutting parameters in CNC turning. The study analyzes the effects of spindle speed, feed rate, depth of cut, and material type on surface roughness and material removal rate during CNC turning operations. Experiments were designed using Taguchi's orthogonal array and analyzed using ANOVA. The results showed that spindle speed and feed rate significantly affect surface roughness, while depth of cut significantly affects material removal rate. Optimal parameters were identified for minimum surface roughness and maximum material removal rate.
Experimental investigation of ohns surface property and process parameter on ...ila vamsi krishna
This document discusses optimization of CNC milling operations. It investigates machining performance using different cutting speeds, feeds, and depths of cut with side and face milling cutters. Surface roughness was evaluated using Taguchi design of experiments and analysis of variance. The Taguchi method was used to formulate the experimental design and optimize milling parameters like speed, feed, and depth of cut. Analysis of variance and signal-to-noise ratios were used to study performance characteristics in milling operations.
This document summarizes an experimental study that optimized machining parameters for turning EN24 alloy steel using the Taguchi method. Five parameters were investigated at three levels each: cutting speed, feed rate, depth of cut, nose radius, and cutting environment (wet vs. dry). Experiments were conducted according to an L18 orthogonal array design. The responses measured were surface roughness and material removal rate (MRR). Optimal parameters were identified that minimized surface roughness and maximized MRR. The Taguchi method was employed to efficiently analyze the large parameter space with a small number of experiments.
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Hokotol-Engineering-Machinability-brochure
1. Aluminium for mould and tool construction
Machinability of GIANTAL, WELDURAL and HOKOTOL
2. Machinability of special alloys
Aleris Rolled & Extruded Products - Eu-
rope, a division of Aleris International, Inc.
(based in Beachwood, Ohio (U.S.A.)), is
one of the world’s leading suppliers of
high quality aluminium products.
Annually more than 500,000 tons of semi-
finished highly specialized and customized
products for a wide variety of end users
are manufactured and supplied worldwide
using plants located in Koblenz, Bonn,
Vogt and Bitterfeld (Germany), Duffel
(Belgium) and Tianjin (China).
The prerequisites are state-of-the-art
production plants, process- and prod-
uct-oriented research and development,
a comprehensive quality management
system, sound marketing and distribu-
tion structures as well as healthy, safe
and environmentally-friendly working
conditions; success, however, is primarily
based on highly skilled and motivated
employees.
As a result of both experience and
know-how, which have been gained by
being the principal supplier to many in-
dustries, and continuous investment in
the prerequisites, products have been
improved continually to satisfy fully the
requirements of the tool- and mould-
making industry.
Photo on the title page with friendly permission of
Handtmann, Germany.
2
3. Machinability of special alloys
The term machinability refers to the ge-
neral suitability of a material for machi-
ning, e. g. drilling, turning or milling. It
describes the way in which a material
can be cut, taking all properties into ac-
count – i. e. its resistance to machining
and how it influences the quality of the
finished part.
Machinability should always be consi-
dered in conjunction with the machining
processes used, and thus also the tool
and the cutting conditions. In terms of
design and manufacture, machinability
is extremely important for the selection
of the material and manufacturing pro-
cess.
A material with good machining proper-
ties is distinguished by the following:
a. after machining, the surface of the
workpiece is smooth and
b. the chips produced during machining
are short-brittle and therefore can be
easily transported, so that they do
not interfere with processing (= short-
brittle spiral and helicalchips).
Disregarding the large number of diffe-
rent machining processes, there are a
few assessment criteria which can be
employed to differing extents in order
to document and check general machi-
nability:
• cutting force
• tool life
(or tool life travel, tool life quantity)
• surface quality of the workpiece
• chip shape
These assessment criteria, in turn, are
influenced to varying degrees by the
following factors:
• material (type, structure)
• tool (cutting material, geometry
level of wear)
• cutting conditions (feed motion,
depth of cut, cutting speed, cutting
edge angle, cooling, lubrication)
Together with the laboratory Corus Re-
search, Development and Technology
(CRD&T) in IJmuiden (The Netherlands)
and Prof. Dr. Kaufeld from the Ulm Uni-
versity of Applied Sciences (Germany),
selected machining processes have
been used to examine the machina-
bility of the aluminium wrought alloys,
GIANTAL, WELDURAL and HOKOTOL,
which have been specially developed
for mould and tool construction.
The results – which are illustrated on the
following pages of the brochure “Alu-
minium for mould and tool construction:
Machinability of GIANTAL, WELDURAL
and HOKOTOL” – show that, in the case
of all the machining processes used,
the selection of a suitable commercially
available tool and use of the correct
cutting conditions make it possible to
influence the machinability of the alloys
GIANTAL, WELDURAL and HOKOTOL to
such an extent that, following process-
ing, the workpiece has a smooth surface
(measured as arithmetical mean rough-
ness value (Ra
)*1
and mean roughness
depth (peak to valley) (Rz
)*2
) and the
chips produced during cutting can be
categorized as short-brittle spiral and
helical chips.
*1
Ra
= arithmetical mean roughness value
The arithmetical mean roughness value Ra
, signifying the roughness parameter, is a value that is
recognized and used internationally. It denotes the arithmetical mean value of the absolute values of the
profile deviations within the sample area. The numerical value of Ra
is always smaller than the Rz
reading
derived from the same sample.
*2
Rz
= mean roughness depth (peak to valley)
The mean roughness depth (peak to valley) Rz
denotes the mean roughness depth, i. e. the arithmetical
mean of the highest single measurements of several single adjacent tracing sections.
Machinability
of GIANTAL, WELDURAL und HOKOTOL
3
4. Machinability of special alloys
Face milling – Roughing
Tool parameter
Tool type Milling tool with renewable cutters Milling tool with renewable cutters Milling tool with renewable cutters
Tool producer / type of tool Walter, F3040.B.063.Z04.20 R4 Walter, F3042.B.050.Z05.15 Walter, F3040-100026
Diameter 63 mm (2.48 ins) 50 mm (1.97 ins) 40 mm (1.57 ins)
Number of cutters 4 5 3
Material of cutters ZDGT200540R-K85 WMG 40 APHT 15T3 PDR-K88 WK 10 ZDGT200540R-K85 WMG 40
Corner radius of cutter 4 mm (0.1575 ins) 0.8 mm (0.0315 ins) 4 mm (0.1575 ins)
Tool design
Milling parameter
Cutting speed (vc
) 942 m/min (3,090 ft/min) 942 m/min (3,090 ft/min) 1,885 m/min (6,184 ft/min)
Spindle speed (n) 4,760 rev/min 6,000 rev/min 15,000 rev/min
Feed per tooth (fz
) 0.15 mm (0.0059 ins) 0.15 mm (0.0059 ins) 0.3 mm (0.0118 ins)
Axial infeed rate (ap
) 4 mm (0.1575 ins) 4 mm (0.1575 ins) 4 mm (0.1575 ins)
Radial infeed rate (ae
) 58 mm (2.28 ins) 45 mm (1.77 ins) 32 mm (1.26 ins)
Cooling lubricant Emulsion (5%) Emulsion (5%) Dry
Spray cooling (FD 1-30) Spray cooling (FD 1-30) Spray cooling (FD 1-30)
GIANTAL: Roughness at the milled surface
Ra
(µm) 0.6-0.7 (Emulsion [5%]) 0.2-0.3 (Emulsion [5%]) 0.5-0.7 (Dry)
Rz
(µm) 3.2-3.4 (Emulsion [5%]) 1.4-1.6 (Emulsion [5%]) 3.2-3.4 (Dry)
Ra
(µm) 0.4-0.5 (Spray Cooling [FD 1-30]) 0.1-0.3 (Spray Cooling [FD 1-30]) 0.4-0.6 (Spray Cooling [FD 1-30])
Rz
(µm) 2.3-2.5 (Spray Cooling [FD 1-30]) 1.2-1.4 (Spray Cooling [FD 1-30]) 2.8-3.0 (Spray Cooling [FD 1-30])
Chip shape Emulsion Spray Cooling Emulsion Spray Cooling Dry Spray Cooling
WELDURAL: Roughness at the milled surface
Ra
(µm) 0.2-0.4 (Emulsion [5%]) 0.2-0.4 (Emulsion [5%]) 0.6-0.8 (Dry)
Rz
(µm) 2.4-2.6 (Emulsion [5%]) 1.6-1.8 (Emulsion [5%]) 4.1-4.3 (Dry)
Ra
(µm) 0.3-0.5 (Spray Cooling [FD 1-30]) 0.2-0.4 (Spray Cooling [FD 1-30]) 0.6-0.8 (Spray Cooling [FD 1-30])
Rz
(µm) 2.8-3.0 (Spray Cooling [FD 1-30]) 1.7-1.9 (Spray Cooling [FD 1-30]) 4.4-4.6 (Spray Cooling [FD 1-30])
Chip shape Emulsion Spray Cooling Emulsion Spray Cooling Dry Spray Cooling
HOKOTOL: Roughness at the milled surface
Ra
(µm) 0.3-0.5 (Emulsion [5%]) 0.2-0.3 (Emulsion [5%]) 0.6-0.8 (Dry)
Rz
(µm) 2.3-2.5 (Emulsion [5%]) 1.6-1.8 (Emulsion [5%]) 4.4-4.6 (Dry)
Ra
(µm) 0.3-0.5 (Spray Cooling [FD 1-30]) 0.2-0.4 (Spray Cooling [FD 1-30]) 0.6-0.8 (Spray Cooling [FD 1-30])
Rz
(µm) 2.5-2.7 (Spray Cooling [FD 1-30]) 1.8-2.0 (Spray Cooling [FD 1-30]) 4.4-4.6 (Spray Cooling [FD 1-30])
Chip shape Emulsion Spray Cooling Emulsion Spray Cooling Dry Spray Cooling
4
5. Machinability of special alloys
Groove milling – Roughing
Tool parameter
Tool type Milling tool with renewable cutters Shank end milling tool Shank end milling tool
Tool producer / type of tool Walter, F3040.H63A.025.Z02.15 R4 25x25/R4 61-3385 DK460F Jabro SMG Diam. 10x14, JH 40
Diameter 25 mm (0.98 ins) 25 mm (0.98 ins) 10 mm (0.39 ins)
Number of cutters 2 3 2
Material of cutters ZDGT150440R-K85 WMG 40 HM HM
Corner radius of cutter 2 mm (0.0787 ins) 4 mm (1.575 ins) 0.1 mm (0.0039 ins)
Tool design
Milling parameter
Cutting speed (vc
) 1,021 m/min (3,350 ft/min) 1,021 m/min (3,350 ft/min) 471 m/min (1,545 ft/min)
Spindle speed (n) 13,000 rev/min 13,000 rev/min 15,000 rev/min
Feed per tooth (fz
) 0.2 mm (0.0079 ins) 0.2 mm (0.0079 ins) 0.15 mm (0.0059 ins)
Axial infeed rate (ap
) 5 mm (0.1969 ins) 5 mm (0.1969 ins) 5 mm (0.1969 ins)
Radial infeed rate (ae
) 25 mm (0.98 ins) 25 mm (0.98 ins) 10 mm (0.39 ins)
Cooling lubricant Spray cooling (FD 1-30) Spray cooling (FD 1-30) Spray cooling (FD 1-30)
Ship volume over time (Q) 650 cm3/min (39.67 ins3
/min) 975 cm3/min (59.50 ins3
/min) –
GIANTAL: Roughness at the milled surface
Ra
(µm) 0.5-0.7 1.4-1.6 2.6-2.8
Rz
(µm) 2.9-3.1 7.3-7.5 11.2-11.4
Chip shape
WELDURAL: Roughness at the milled surface
Ra
(µm) 0.8-1.0 1.0-1.2 2.8-3.0
Rz
(µm) 3.6-3.8 5.9-6.1 12.8-13.0
Chip shape
HOKOTOL: Roughness at the milled surface
Ra
(µm) 0.5-0.7 0.9-1.1 3.5-3.7
Rz
(µm) 3.3-3.5 5.9-6.1 13.5-13.7
Chip shape
5
6. Machinability of special alloys
Finishing (with shank end milling tool)
Tool parameter
Tool type Shank end milling tool
Tool producer / type of tool Jabro SMG Diameter 10x14, JH 40
Diameter 10 mm (0.39 ins)
Number of cutters 2
Material of cutters HM
Corner radius of cutter 0.1 mm (0.0039 ins)
Tool design
Milling parameter
Cutting speed (vc
) 283 m/min (928 ft/min) 565 m/min (1,854 ft/min) 565 m/min (1,854 ft/min)
Spindle speed (n) 9,000 rev/min 18,000 rev/min 18,000 rev/min
Feed per tooth (fz
) 0.1 mm (0.0039 ins) 0.1 mm (0.0039 ins) 0.005 mm (0.0002 ins)
Axial infeed rate (ap
) 0.18 mm (0.0071 ins) 0.18 mm (0.0071 ins) 0.18 mm (0.0071 ins)
Radial infeed rate (ae
) 9.6 mm (0.3780 ins) 9.6 mm (0.3780 ins) 9.6 mm (0.3780 ins)
Cooling lubricant Dry Dry Dry
GIANTAL: Roughness at the milled surface
Ra
(µm) 0.5-0.7 0.8-1.0 0.1-0.3
Rz
(µm) 4.1-4.3 4.3-4.5 1.6-1.8
Chip shape
WELDURAL: Roughness at the milled surface
Ra
(µm) 1.4-1.6 1.7-1.9 0.1-0.3
Rz
(µm) 6.2-6.4 7.0-7.2 1.2-1.4
Chip shape
HOKOTOL: Roughness at the milled surface
Ra
(µm) 1.5-1.7 1.7-1.9 0.3-0.5
Rz
(µm) 7.1-7.3 7.8-8.0 2.9-3.1
Chip shape
6
7. Machinability of special alloys
Finishing (with spherical cutter)
Tool parameter
Tool type Spherical cutter Spherical cutter
Tool producer / type of tool Jabro SMG Diam. 10x8.5, JH 450 Jabro MG Diam. 2x4, HSC
Diameter 10 mm (0.39 ins) 2 mm (0.0787 ins)
Number of cutters 2 2
Material of cutters HM HM
Corner radius of cutter 5 mm (0.1969 ins) 1 mm (0.0394 ins)
Tool design
Milling parameter
Spindle speed (n) 8,000 rev/min (26,246 ft/min) 16,000 rev/min (52,493 ft/min) 8,000 rev/min (26,246 ft/min) 16,000 rev/min (52,493 ft/min)
Feed per tooth (fz
) 0.08 mm (0.0031 ins) 0.08 mm (0.0031 ins) 0.04 mm (0.0016 ins) 0.04 mm (0.0016 ins)
Axial infeed rate (ap
) 0.09 mm (0.0035 ins) 0.18 mm (0.0071 ins) 0.03 mm (0.0012 ins) 0.06 mm (0.0024 ins)
Radial infeed rate (ae
) 0.04 mm (0.0016 ins) 0.08 mm (0.0031 ins) 0.02 mm (0.0008 ins) 0.04 mm (0.0016 ins)
Working angle 60° 60° 60° 60°
Cooling lubricant Dry Dry Dry Dry
Spray cooling (FD 1-30) Spray cooling (FD 1-30) – –
HOKOTOL: Roughness at the milled surface
Ra
(µm) 0.1-0.3 (Dry) 0.1-0.3 (Dry) 0.1-0.3 (Dry) 0.4-0.6 (Dry)
Rz
(µm) 1.1-1.3 (Dry) 1.3-1.5 (Dry) 1.1-1.3 (Dry) 2.5-2.7 (Dry)
Ra
(µm) 0.1-0.3 (Spray Cool. [FD 1-30]) 0.1-0.3 (Spray Cool. [FD 1-30]) – –
Rz
(µm) 1.0-1.2 (Spray Cool. [FD 1-30]) 1.3-1.5 (Spray Cool. [FD 1-30]) – –
GIANTAL: Roughness at the milled surface
Ra
(µm) 0.1-0.3 (Dry) 0.2-0.4 (Dry) 0.2-0.4 (Dry) 0.4-0.6 (Dry)
Rz
(µm) 1.2-1.4 (Dry) 1.6-1.8 (Dry) 2.1-2.3 (Dry) 2.6-2.8 (Dry)
Ra
(µm) 0.1-0.3 (Spray Cool. [FD 1-30]) 0.2-0.4 (Spray Cool. [FD 1-30]) – –
Rz
(µm) 1.2-1.4 (Spray Cool. [FD 1-30]) 1.4-1.6 (Spray Cool. [FD 1-30]) – –
WELDURAL: Roughness at the milled surface
Ra
(µm) 0.1-0.3 (Dry) 0.1-0.3 (Dry) 0.1-0.3 (Dry) 0.4-0.6 (Dry)
Rz
(µm) 1.1-1.3 (Dry) 1.2-1.4 (Dry) 1.3-1.5 (Dry) 3.3-3.5 (Dry)
Ra
(µm) 0.1-0.3 (Spray Cool. [FD 1-30]) 0.1-0.3 (Spray Cool. [FD 1-30]) – –
Rz
(µm) 1.0-1.2 (Spray Cool. [FD 1-30]) 1.3-1.5 (Spray Cool. [FD 1-30]) – –
7
8. Machinability of special alloys
Face milling (with an unsuitable tool design)
Tool parameter
Tool type Milling tool with renewable cutters
Tool producer / type of tool Walter, F3042.B.050.Z05.15
Diameter 50 mm (1.97 ins)
Number of cutters 5
Material of cutters APMT 15T3 PDR-DRR WAP 35
Corner radius of cutter 0.8 mm (0.0315 ins)
Tool design
Milling parameter
Cutting speed (vc
) 628 m/min (3,090 ft/min)
Spindle speed (n) 4,000 rev/min
Feed per tooth (fz
) 0.1 mm (0.0039 ins)
Axial infeed rate (ap
) 4 mm (0.1575 ins)
Radial infeed rate (ae
) 45 mm (1.77 ins)
Cooling lubricant Dry
GIANTAL: Cutter plates, chip shape and workpiece surface after face milling with an unsuitable tool design
WELDURAL: Cutter plates, chip shape and workpiece surface after face milling with an unsuitable tool design
HOKOTOL: Cutter plates, chip shape and workpiece surface after face milling with an unsuitable tool design
Cutter plates before face milling
8
9. Machinability of special alloys
Drilling
Tool parameter
Tool type Drilling tool with renewable cutters Drilling tool Drilling tool
Tool producer / type of tool Walter, B3212.F.028Z01.056R Dormer HSCO Jobber Drills Klenk
Diameter 28 mm (1.10 ins) 13.5 mm (0.53 ins) 2.5 mm (0.10 ins)
Number of cutters 1 2 2
Material of cutters PÜ28475-3 WXP 45 HM HM
Tool design
Drilling parameter
Cutting speed (vc
) 528 m/min (1,732 ft/min) 254 m/min (833 ft/min) 47 m/min (154 ft/min)
Spindle speed (n) 6,000 rev/min 6,000 rev/min 6,000 rev/min
Feed per round (fz
) 0.3 mm (0.0118 ins) 0.2 mm (0.0078 ins) 0.15 mm (0.0059 ins)
Hole deepness 20 mm (0.79 ins) 20 mm (0.79 ins) 20 mm (0.79 ins)
Cooling lubricant Spray cooling (FD 1-30) Spray cooling (FD 1-30) Spray cooling (FD 1-30)
GIANTAL: Chip shape
HOKOTOL: Chip shape
WELDURAL: Chip shape
9
10. Machinability of special alloys
Tool parameter
Tool type Drilling tool
Tool producer / type of tool Klenk
Diameter 6.8 mm (0.2677 ins)
Number of cutters 2
Material of cutters HM
Tool design
Drilling parameter
Cutting speed (vc
) 85 m/min (279 ft/min)
Spindle speed (n) 4,000 rev/min
Feed per round (fz
) 0.08 mm (0.0315 ins)
Hole deepness 40 mm (1.57 ins)
Cooling lubricant Dry
GIANTAL: Chip shape after drilling with an unsuitable tool design
WELDURAL: Chip shape after drilling with an unsuitable tool design
HOKOTOL: Chip shape after drilling with an unsuitable tool design
Drilling (with an unsuitable tool design)
10
11. Machinability of special alloys
The classic alloy: GIANTAL
GIANTAL is a highly developed form of
5083-O which used to be the alloy used
in fabricating the first generation of alu-
minium tools. GIANTAL is distinguished
by significantly low internal stresses,
the property which lends itself to excel-
lent form stability during the process of
milling the plate. The uniformity of its
properties is remarkable, even when
the plate is extremely thick. In addition,
it exhibits good weldability and corro-
sion resistance.
For a non-heat treatable alloy it main-
tains a relatively good strength, even at
elevated temperatures. It is important
to take into account that for many ap-
plications, this alloy might not have suf-
ficient strength. It must also be noted
that its freecutting characteristics are
not as good as hard (heat treatable)
alloys and this must be taken into con-
sideration for machining operations.
The wear resistance of GIANTAL is in
general better than 5083.
The universal alloy: WELDURAL
WELDURAL was introduced as a high
quality material for the mould construction
industry, designed for excellent weld-
ability and high temperature resistance.
Its strength is similar to that of medium
to high strength aluminium alloys.
WELDURAL matches 2017A and 7075
alloys not only in machinability, wear re-
sistance, and capability of being polished,
but it also offers other advantages.
This alloy permanently maintains its re-
latively high strength at temperatures
up to 250°C (482°F). The weldability of
WELDURAL is as good as that of al-
loy 5083. In comparison to alloy 7075,
that typically demonstrates a drop in
strength and higher plate thickness,
WELDURAL maintains a relatively high
strength with no significant dependence
on plate thickness. This characteristic
property of WELDURAL along with its
low internal stress level, ensures excel-
lent machinability and high dimensional
stability.
The high-strength alloy: HOKOTOL
Originally developed as a high-strength
aluminium alloy for the aircraft industry,
this alloy was further developed and op-
timized to satisfy the most demanding
applications of the mould construction
industry. The resulting mould construc-
tion alloy, HOKOTOL, exhibits very high
strength and wear resistance as well as
excellent uniformity of strength prop-
erties. These characteristics offer the
mould builder an excellent machinabil-
ity which remains constant across the
entire thickness of the plate.
HOKOTOL plates are distinguished by
their very high dimensional stability.
Pertaining to surface porosity, they
comply with the most demanding sur-
face requirements.
High-strength aluminium alloys such
as HOKOTOL are generally difficult to
weld. However, repair welding is quite
possible when an appropriate welding
method such as MIG or TIG is used
along with a suitable filler alloy.
Due to higher strength imparted to alu-
minium alloys, they are now used for
applications which were until recently
reserved for low to medium strength
steels.
We would be pleased to supply you
with any further information about
our activities.
Properties and characteristics
of GIANTAL, WELDURAL and HOKOTOL
11