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Aluminum-based MMC machining with diamond-coated cutting tools. S. Durante, G. Rutelli, F. Rabezzana October 1997 Presented by: Nathan Rasmussen. Presentation Outline. Heading     Title of Paper, Author (s), Date

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aluminum based mmc machining with diamond coated cutting tools

Aluminum-based MMC machining with diamond-coated cutting tools

S. Durante, G. Rutelli, F. Rabezzana

October 1997

Presented by: Nathan Rasmussen

presentation outline
Presentation Outline
  • Heading    Title of Paper, Author (s), Date
  • Introduce paper    Function of paper      Why important           References           
  • Models, Design Application    Relate to technical area in course         Parameters defined, design defined      Design principle                             
  • Results    Experimental equipment discussed     Design principles applied                    Data/tables/design discussed             Correlation of results with models   
  • Conclusions    Practical industrial use         Technical advancement         Industries most impacted 
function of paper
Function of Paper
  • Investigation of an alternative solution for machining aluminum metal matrix composites (MMCs)
  • Machining process produces SiC powder and hard particles from tool wear which create a highly abrasive environment.
  • Tool life comparison of:
    • Standard Carbide Tooling
    • Polycrystalline Diamond (PCD) Tooling
    • Chemical-Vapor Deposition (CVD) diamond-coated Tooling
importance
Importance
  • Aero, auto, and train industries are searching for lighter high-strength alloys
  • MMCs fill those needs but have traditionally required more expensive tooling like PCD inserts
  • Chemical-Vapor Deposition (CVD) diamond-coated inserts appear to be a promising alternative
references
References
  • DURALCAN Composites Maching Guidelines, 8/2/1991
  • M.K. Aghajanian, C.A. Anderson, R.J. Wiener and B.R. Rossing. SAE Technical Paper, 950263, February 27-March2, 1995
  • S. Durante, F. Rabezzana and G. Rutelli, in Eurodiamond ’96, Torino, 1996, p. 135.
  • I.E. Clark, IDR Ind. Diam. Rev., 54(3) (1994) 562.
  • S. Durante, in 26th AIM Congress Proceedings, Milano, 1996.
  • M. Eastman and C. Lane, Cutting Tool Engineering, October (1993).
relationship to course
Relationship to Course
  • Tool life criteria – flank wear
  • Some of their data could have been fit to the Taylor’s tool life equation -- vTn = C
  • Coating technology & insert parameters
design parameters
Design Parameters
  • Benchmarks + 3 different CVD diamond-coated inserts
  • Two speeds & three depths of cut
  • Three test materials
  • Tool life criterion - .4mm average flank wear
design principles
Design Principles
  • Tool Material
  • Tool Geometry
  • Coatings
experimental equipment
Experimental Equipment
  • Turning - all inserts tested with turning
    • All operations done on a SAG 101 Graziano Lathe equipped with a dynamometric device
    • Machine Capacity: P = 60 kW and n = 5000 rev/min
    • Inserts installed on a CSBPR 20 20 K 12 Tool Holder
  • Milling – Machine tool not specified
    • Did not test CVD diamond-coated inserts with this setup
  • Drilling – Machine tool not specified
    • Did not test CVD diamond-coated inserts with this setup
applied design principles
Applied Design Principles
  • Coating technology for depositing thin layers of diamond (hot filament and DC plasma jet CVD processes)
  • Applied a chamfer to CVD diamond coated tools to redistribute the force load on the edge
  • Did not take the opportunity to fit data to the Taylor’s tool life model
benchmark turning test results
Benchmark Turning Test Results
  • Standard carbide cutting tools with TiN coatings have relatively short lives
  • PCD tools last 2.5 to 7 times longer depending on MMC composition
turning with a 15 m m cvd diamond coated insert
Turning with a 15 mm CVD Diamond-Coated Insert
  • Y axis in seconds? – chipping was still a significant problem
turning with a 30 m m cvd diamond coated insert
Turning with a 30 mm CVD Diamond-Coated Insert
  • Changed the surface pretreatment
  • Added a 15 degree x 0.1 mm chamfer
turning with a 30 m m cvd diamond coated insert1
Turning with a 30 mm CVD Diamond-Coated Insert
  • Changed the surface pretreatment
  • Added a 15 degree x 0.1 mm chamfer
pcd vs pcd coated inserts
PCD vs PCD Coated Inserts
  • 30 mm coated tool lasted roughly half that of a PCD tool
  • CVD inserts are indexible so may be worth the cost
  • If better organized then could have come up with some Taylor tool life constants for CVD inserts.
conclusions
Conclusions
  • Thick CVD diamond coatings worked while thinner ones were prone to chipping
  • The substrate surface preparation has a significant impact on adhesion of coating
  • Course substrates are better than fine ones
  • Diamond-coated tool life still cannot be compared to PCD tool life
  • No real solid data or models for predicting the life of a CVD diamond-coated tool
practical industrial use
Practical Industrial Use
  • Machining any nonferrous materials such as plain aluminum alloys or titanium
  • Machining Aluminum based MMCs with Al2O3 and SiC
technology advancement 1
Technology Advancement1
  • CVD Diamond-Coated Inserts
    • Price is around $50 - $70 for indexible quad
    • Capable of high speed machining up to 6000 sfpm
    • Recommend using high pressure coolant for interface integrity
    • "Their commercial viability is proven. They can do the work and, in some applications, they are the only way to do the work."
  • PCD Inserts
    • Price is around $80 - $100 per insert for single point
    • They can now be formed with complex geometry
    • Still last longer than CVD diamond-coated inserts
  • Diamond-Coated Carbide Inserts-Ready, Set, Go! by Chris Koepfer, Senior Editor
industries most impacted
Industries Most Impacted
  • PCD insert industry
  • Aerospace
  • Automotive
  • Trains
  • Racing
  • Any other industry looking for a lighter high-strength material that can be machined