Phase equilibria and thermodynamic properties of high-alloy tool steels : theoretical and experimental approach

OpenAIRE

Bratberg, Johan

2005-01-01

The recent development of tool steels and high-speed steels has led to a significant increase in alloy additions, such as Co, Cr, Mo, N, V, and W. Knowledge about the phase relations in these multicomponent alloys, that is, the relative stability between different carbides or the solubility of different elements in the carbides and in the matrix phase, is essential for understanding the behaviour of these alloys in heat treatments. This information is also the basis for improving the properti...

Laser Cladding of CPM Tool Steels on Hardened H13 Hot-Work Steel for Low-Cost High-Performance Automotive Tooling

Science.gov (United States)

Chen, J.; Xue, L.

2012-06-01

This paper summarizes our research on laser cladding of high-vanadium CPM® tool steels (3V, 9V, and 15V) onto the surfaces of low-cost hardened H13 hot-work tool steel to substantially enhance resistance against abrasive wear. The results provide great potential for fabricating high-performance automotive tooling (including molds and dies) at affordable cost. The microstructure and hardness development of the laser-clad tool steels so obtained are presented as well.

Tool life and cutting speed for the maximum productivity at the drilling of the stainless steel X22CrMoV12-1

Science.gov (United States)

Vlase, A.; Blăjină, O.; Iacob, M.; Darie, V.

2015-11-01

Two addressed issues in the research regarding the cutting machinability, establishing of the optimum cutting processing conditions and the optimum cutting regime, do not yet have sufficient data for solving. For this reason, in the paper it is proposed the optimization of the tool life and the cutting speed at the drilling of a certain stainless steel in terms of the maximum productivity. For this purpose, a nonlinear programming mathematical model to maximize the productivity at the drilling of the steel is developed in the paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the numerical mathematical model. Using this proposed model allows increasing the accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The results presented in this paper can be used in the production activity, in order to increase the productivity of the stainless steels machining. Also new research directions for the specialists in this interested field may come off from this paper.

The electrogas and electroslag multipass high speed welding of nuclear pressure vessel steels

International Nuclear Information System (INIS)

Eichhorn, F.; Hirsch, P.; Langenbahn, H.W.; Wubbels, B.

1978-01-01

High-speed electroslag and electrogas welding of 15 Mn Ni63 steel plates to achieve high strength and toughness joints for reactor pressure vessels are described. Mechanical testing of overheating-resistant, brittle fracture resistant low alloy steels is discussed. (UK)

Research on the tool holder mode in high speed machining

Science.gov (United States)

Zhenyu, Zhao; Yongquan, Zhou; Houming, Zhou; Xiaomei, Xu; Haibin, Xiao

2018-03-01

High speed machining technology can improve the processing efficiency and precision, but also reduce the processing cost. Therefore, the technology is widely regarded in the industry. With the extensive application of high-speed machining technology, high-speed tool system has higher and higher requirements on the tool chuck. At present, in high speed precision machining, several new kinds of clip heads are as long as there are heat shrinkage tool-holder, high-precision spring chuck, hydraulic tool-holder, and the three-rib deformation chuck. Among them, the heat shrinkage tool-holder has the advantages of high precision, high clamping force, high bending rigidity and dynamic balance, etc., which are widely used. Therefore, it is of great significance to research the new requirements of the machining tool system. In order to adapt to the requirement of high speed machining precision machining technology, this paper expounds the common tool holder technology of high precision machining, and proposes how to select correctly tool clamping system in practice. The characteristics and existing problems are analyzed in the tool clamping system.

Comparative study of AISI M3:2 high speed steel produced through different techniques of manufacturing

International Nuclear Information System (INIS)

Araujo Filho, Oscar Olimpio de

2006-01-01

In this work AISI M3:2 high speed steels obtained through different techniques of manufacturing, submitted to the same heat treatment procedure were evaluated by measuring their mechanical properties of transverse rupture strength and hardness. Sinter 23 obtained by hot isostatic pressing (HIP), VWM3C obtained by the conventional route and a M3:2 high speed steel obtained by cold compaction of water atomized powders and vacuum sintered with and without the addition of a small quantity of carbon were evaluated after the same heat treatment procedure. The vacuum sintered M3:2 high speed steel can be an alternative to the more expensive high speed steel produced by hot isostatic pressing and with similar properties presented by the conventional one. The characterization of the vacuum sintered M3:2 high speed steel was performed by measuring the densities of the green compacts and after the sintering cycle. The sintering produced an acceptable microstructure and densities near to the theoretical. The transverse rupture strength was evaluated by means of three point bending tests and the hardness by means of Rockwell C and Vickers tests. The technique of scanning electronic microscopy (SEM) was used to evaluate the microstructure and to establish a relation with the property of transverse rupture strength. The structure was determined by means of X-ray diffraction (XRD) patterns and the retained austenite was detected to all the conditions of heat treatment. The main contribution of this work is to establish a relation between the microstructure and the mechanical property of transverse rupture strength and to evaluate the AISI M3:2 vacuum sintered high speed steel as an alternative to the similar commercial high speed steels. (author)

Machining tools in AISI M2 high-speed steel obtained by spray forming process

International Nuclear Information System (INIS)

Jesus, Edilson Rosa Barbosa de.

2004-01-01

The aim of the present work was the obtention of AISI M2 high-speed steel by spray forming technique and the material evaluation when used as machining tool. The obtained material was hot rolled at 50% and 72% reduction ratios, and from which it was manufactured inserts for machining tests. The performance of inserts made of the spray formed material was compared to inserts obtained from conventional and powder metallurgy (MP) processed materials. The spray formed material was chemical, physical, mechanical and microstructural characterised. For further characterisation, the materials were submitted to machining tests for performance evaluation under real work condition. The results of material characterisation highlight the potential of the spray forming technique, in the obtention of materials with good characteristics and properties. Under the current processing, hot rolling and heat treatments condition, the analysis of the results of the machining tests revealed a very similar behaviour among the tested materials. Proceeding a criterious analysis of the machining results tests, it was verified that the performance presented by the powder metallurgy material (MP) was slight superior, followed by conventional obtained material (MConv), which presented a insignificant advantage over the spray formed and hot rolled (72% reduction ratio) material. The worst result was encountered for the spray forming and hot rolled (50% reduction ratio) material that presented the highest wear values. (author)

GRINDABILITY OF SELECTED GRADES OF LOW-ALLOY HIGH-SPEED STEEL

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Jan Jaworski

2016-09-01

Full Text Available In this paper, we presents the results of investigations studied the cutting ability and grindability of selected high-speed steels. We analysed the effect of the austenitization temperature on the grain size, the amount of retained austenite and percentage of retained austenite in HS3-1-1 steel. Furthermore, the investigations concerned on the efficiency of the keyway broaches during the whole period of operation were carried out. It was found that the value of average roughness parameter increases together with increases in the grinding depth. The investigations also show the influence of tempering conditions on the volume of carbide phases in HS3-1-1 steel.

Predicting the Abrasion Resistance of Tool Steels by Means of Neurofuzzy Model

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Dragutin Lisjak

2013-07-01

Full Text Available This work considers use neurofuzzy set theory for estimate abrasion wear resistance of steels based on chemical composition, heat treatment (austenitising temperature, quenchant and tempering temperature, hardness after hardening and different tempering temperature and volume loss of materials according to ASTM G 65-94. Testing of volume loss for the following group of materials as fuzzy data set was taken: carbon tool steels, cold work tool steels, hot work tools steels, high-speed steels. Modelled adaptive neuro fuzzy inference system (ANFIS is compared to statistical model of multivariable non-linear regression (MNLR. From the results it could be concluded that it is possible well estimate abrasion wear resistance for steel whose volume loss is unknown and thus eliminate unnecessary testing.

Research of x-ray nondestructive detector for high-speed running conveyor belt with steel wire ropes

Science.gov (United States)

Wang, Junfeng; Miao, Changyun; Wang, Wei; Lu, Xiaocui

2008-03-01

An X-ray nondestructive detector for high-speed running conveyor belt with steel wire ropes is researched in the paper. The principle of X-ray nondestructive testing (NDT) is analyzed, the general scheme of the X-ray nondestructive testing system is proposed, and the nondestructive detector for high-speed running conveyor belt with steel wire ropes is developed. The hardware of system is designed with Xilinx's VIRTEX-4 FPGA that embeds PowerPC and MAC IP core, and its network communication software based on TCP/IP protocol is programmed by loading LwIP to PowerPC. The nondestructive testing of high-speed conveyor belt with steel wire ropes and network transfer function are implemented. It is a strong real-time system with rapid scanning speed, high reliability and remotely nondestructive testing function. The nondestructive detector can be applied to the detection of product line in industry.

The effect of product quality on the integrity of advanced surface engineering treatments applied to high speed steel circular saw blades

International Nuclear Information System (INIS)

Bradbury, S.R.; Sarwar, M.

1996-01-01

Advanced surface engineering technologies have been successfully applied to high speed steel drills and carbide single-point cutting tools, but, as yet, limited benefits have been realized when applying the same technologies to multi-point cutting tools of commercial quality. This paper discusses the factors that have limited the benefits of advanced surface engineering treatments when applied to high speed steel circular saw blades. Common manufacturing defects have been identified on the teeth of the blades. Tests which evaluate the blade performance throughout its useful life and examination by scanning electron microscopy (SEM) have shown that these defects adversely affect the performance and wear resistance of surface engineered blades. Further investigations suggest that significant improvements in coating integrity can be achieved through the careful preparation of the substrate surface and refinement of the cutting edge geometry prior to treatment. For this application, the need for refinement and enhancement of current manufacturing practices is demonstrated if the full benefits of advanced surface engineering are to be realized. (orig.)

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

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Kiprawi Mohammad Ashaari

2017-01-01

Full Text Available A wear of cutting tools during machining process is unavoidable due to the presence of frictional forces during removing process of unwanted material of workpiece. It is unavoidable but can be controlled at slower rate if the cutting speed is fixed at certain point in order to achieve optimum cutting conditions. The wear of cutting tools is closely related with the thermal deformations that occurred between the frictional contact point of cutting edge of cutting tool and workpiece. This research paper is focused on determinations of relationship among cutting temperature, cutting speed, cutting forces and radial depth of cutting parameters. The cutting temperature is determined by using the Indium Arsenide (InAs and Indium Antimonide (InSb photocells to measure infrared radiation that are emitted from cutting tools and cutting forces is determined by using dynamometer. The high speed machining process is done by end milling the outer surface of carbon steel. The signal from the photocell is digitally visualized in the digital oscilloscope. Based on the results, the cutting temperature increased as the radial depth and cutting speed increased. The cutting forces increased when radial depth increased but decreased when cutting speed is increased. The setup for calibration and discussion of the experiment will be explained in this paper.

Experimental evaluation of tool wear throughout a continuous stroke blanking process of quenched 22MnB5 ultra-high-strength steel

Science.gov (United States)

Vogt, S.; Neumayer, F. F.; Serkyov, I.; Jesner, G.; Kelsch, R.; Geile, M.; Sommer, A.; Golle, R.; Volk, W.

2017-09-01

Steel is the most common material used in vehicles’ chassis, which makes its research an important topic for the automotive industry. Recently developed ultra-high-strength steels (UHSS) provide extreme tensile strength up to 1,500 MPa and combine great crashworthiness with good weight reduction potential. However, in order to reach the final shape of sheet metal parts additional cutting steps such as trimming and piercing are often required. The final trimming of quenched metal sheets presents a huge challenge to a conventional process, mainly because of the required extreme cutting force. The high cutting impact, due to the materials’ brittleness, causes excessive tool wear or even sudden tool failure. Therefore, a laser is commonly used for the cutting process, which is time and energy consuming. The purpose of this paper is to demonstrate the capability of a conventional blanking tool design in a continuous stroke piercing process using boron steel 22MnB5 sheets. Two different types of tool steel were tested for their suitability as active cutting elements: electro-slag remelted (ESR) cold work tool steel Bohler K340 ISODUR and powder-metallurgic (PM) high speed steel Bohler S390 MICROCLEAN. A FEM study provided information about an optimized punch design, which withstands buckling under high cutting forces. The wear behaviour of the process was assessed by the tool wear of the active cutting elements as well as the quality of cut surfaces.

Tool life and surface roughness of ceramic cutting tool when turning AISI D2 tool steel

International Nuclear Information System (INIS)

Wan Emri Wan Abdul Rahaman

2007-01-01

The tool life of physical vapor deposition (PVD) titanium nitride (TiN) coated ceramic when turning AISI D2 tool steel of hardness 54-55 HRC was investigated. The experiments were conducted at various cutting speed and feed rate combinations with constant depth of cut and under dry cutting condition. The tool life of the cutting tool for all cutting conditions was obtained. The tool failure mode and wear mechanism were also investigated. The wear mechanism that is responsible for the wear form is abrasion and diffusion. Flank wear and crater wear are the main wear form found when turning AISI D2 grade hardened steel with 54-55 HRC using KY 4400 ceramic cutting tool. Additionally catastrophic failure is observed at cutting speed of 183 m/min and feed rate of 0.16 mm/ rev. (author)

Evaluation of Hole Quality in Hardened Steel with High-Speed Drilling Using Different Cooling Systems

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Lincoln Cardoso Brandão

2011-01-01

Full Text Available This work evaluates the hole quality on AISI H13 hardened steel using high-speed drilling. Specimens were machined with new and worn out drills with 8.6 mm diameter and (TiAlN coating. Two levels of cutting speed and three levels of cooling/lubrication systems (flooded, minimum lubrication quantity, and dry were used. The hole quality is evaluated on surface roughness (Ra parameter, diameter error, circularity, and cylindricity error. A statistical analysis of the results shows that the cooling/lubrication system significantly affects the hole quality for all measured variables. This analysis indicates that dry machining produces the worst results. Higher cutting speeds not only prove beneficial to diameter error and circularity errors, but also show no significant difference on surface roughness and cylindricity errors. The effects of the interaction between the cooling/lubrication systems, tool wear, and cutting speed indicate that only cylindricity error is influenced. Thus, the conclusion is that the best hole quality is produced with a higher cutting speed using flooded or minimum lubrication quantity independent of drill wear.

Microstructure and properties of powder metallurgy (PM) high alloy tool steels

International Nuclear Information System (INIS)

Wojcieszynski, A.L.; Eisen, W.B.; Dixon, R.B.

1998-01-01

Particle metallurgy (PM) processing is currently the primary manufacturing method used to produce advanced high alloy tool steel compositions for use in industrial tooling applications. This process involves gas atomization of the pre-alloyed melt to form spherical powders and consolidation by HIP to full density. The HIP product may be used directly in select applications, but is usually subjected to additional forging to improve properties and produce a wide range of bar and plate sizes. Compared to ingot-cast tool steels, PM tool steels have very homogeneous microstructures with very fine carbide and sulfide size distributions, free from carbide banding, which results in improved machinability, grindability, and mechanical properties. In addition, this technology enables the development of advanced tool steel compositions which could not be economically produced by conventional steelmaking. (author)

High Thermal Conductivity and High Wear Resistance Tool Steels for cost-effective Hot Stamping Tools

Science.gov (United States)

Valls, I.; Hamasaiid, A.; Padré, A.

2017-09-01

In hot stamping/press hardening, in addition to its shaping function, the tool controls the cycle time, the quality of the stamped components through determining the cooling rate of the stamped blank, the production costs and the feasibility frontier for stamping a given component. During the stamping, heat is extracted from the stamped blank and transported through the tool to the cooling medium in the cooling lines. Hence, the tools’ thermal properties determine the cooling rate of the blank, the heat transport mechanism, stamping times and temperature distribution. The tool’s surface resistance to adhesive and abrasive wear is also an important cost factor, as it determines the tool durability and maintenance costs. Wear is influenced by many tool material parameters, such as the microstructure, composition, hardness level and distribution of strengthening phases, as well as the tool’s working temperature. A decade ago, Rovalma developed a hot work tool steel for hot stamping that features a thermal conductivity of more than double that of any conventional hot work tool steel. Since that time, many complimentary grades have been developed in order to provide tailored material solutions as a function of the production volume, degree of blank cooling and wear resistance requirements, tool geometries, tool manufacturing method, type and thickness of the blank material, etc. Recently, Rovalma has developed a new generation of high thermal conductivity, high wear resistance tool steel grades that enable the manufacture of cost effective tools for hot stamping to increase process productivity and reduce tool manufacturing costs and lead times. Both of these novel grades feature high wear resistance and high thermal conductivity to enhance tool durability and cut cycle times in the production process of hot stamped components. Furthermore, one of these new grades reduces tool manufacturing costs through low tool material cost and hardening through readily

High-speed fiber laser cutting of thick stainless steel for dismantling tasks

Science.gov (United States)

Shin, Jae Sung; Oh, Seong Yong; Park, Hyunmin; Chung, Chin-Man; Seon, Sangwoo; Kim, Taek-Soo; Lee, Lim; Choi, Byung-Seon; Moon, Jei-Kwon

2017-09-01

A high-speed fiber laser cutting technology of thick steels for dismantling tasks was achieved using a 6-kW fiber laser system. At first, a new cutting head for efficient cutting of thick steels was developed, which was composed by a collimator with a focal length of 160 mm and mirror-type focusing objects with a long focal length of 600 mm. The long focal length of the focusing object made it possible for the beam size to be small through the thick cutting material and the cutting efficiency was expected to increase compared with the short focal length. In addition, folding the beam facilitated the compact cutting head with a size of 160 mm (width) × 80 mm (height) × 640 mm (length) and a weight of 6.9 kg. In the cutting experiment, the laser beam was delivered to the cutting head by a 25-m long process fiber with a core diameter of 100 μm. The cutting performances were studied against the thicknesses of stainless steel plates. A maximum cutting speed of 72 mm/min was obtained for the 60-mm thick stainless steel plate cutting and the cut specimen showed an excellent kerf shape and a narrow kerf width. To the best of our knowledge, this cutting speed was higher than other previously reported results when cutting with a 6-kW laser power.

Tooling device design for vibration-assisted high speed shaping of PMMA

International Nuclear Information System (INIS)

Mostofa, Md. Golam; Noh, J. H.; Kim, H. Y.; Ahn, J. H.; Kang, D. B.

2010-01-01

PMMA optical components that are used as one of the most important parts of high precision equipment and machines are increasingly replacing the glass due to the various advantages of PMMA. Especially in Light Guide Panels, the PMMA sheet that is used in Liquid Crystal Displays plays an important role in scattering the incident light and requires very fine machining as the sheet is directly related to the optical characteristics of the panels. The High Speed End milling and High Speed Shaping processes that are widely adopted and applied to the precise machining of Light Incident Plane still have quality problems, such as cracks, breakages, poor waviness, and straightness. This paper presents the tooling device design for machining a Light Incident Plane through vibration-assisted High Speed Shaping for increasing the optical quality by minimizing the above-mentioned problems. The cutting tool and the tool post presented in this paper are designed by the authors to increase the magnitude of the cutting stroke by adopting the resonant frequency without weakening the stiffness and to reduce vibrations during even high speed feeding. The dynamic characteristics of the cutting tool and the tool post are evaluated through simulation and experiment as well. The results reveal very appropriate dynamic characteristics for vibration-assisted High Speed Shaping

Optimization and Simulation of SLM Process for High Density H13 Tool Steel Parts

Science.gov (United States)

Laakso, Petri; Riipinen, Tuomas; Laukkanen, Anssi; Andersson, Tom; Jokinen, Antero; Revuelta, Alejandro; Ruusuvuori, Kimmo

This paper demonstrates the successful printing and optimization of processing parameters of high-strength H13 tool steel by Selective Laser Melting (SLM). D-Optimal Design of Experiments (DOE) approach is used for parameter optimization of laser power, scanning speed and hatch width. With 50 test samples (1×1×1cm) we establish parameter windows for these three parameters in relation to part density. The calculated numerical model is found to be in good agreement with the density data obtained from the samples using image analysis. A thermomechanical finite element simulation model is constructed of the SLM process and validated by comparing the calculated densities retrieved from the model with the experimentally determined densities. With the simulation tool one can explore the effect of different parameters on density before making any printed samples. Establishing a parameter window provides the user with freedom for parameter selection such as choosing parameters that result in fastest print speed.

Residual stress in a M3:2 PM high speed steel; effect of mechanical loading

DEFF Research Database (Denmark)

Højerslev, Christian; Odén, Magnus; Carstensen, Jesper V.

2001-01-01

X-ray lattice strains were investigated in an AISI M3:2 PM high-speed steel in the as heat treated condition and after exposure to alternating mechanical load. The volume changes during heat treatment were monitored with dilatometry. Hardened and tempered AISI M3:2 steel consists of tempered lath...

Influence of quenching parameters in the carbides presence in the AISI M2 high speed steel

International Nuclear Information System (INIS)

Magalhaes, A.S.; Maria, G.G.B; Martins, S.C.S.; Lopes, W.; Correa, E.C.S.; Bezerra, A.C.S.

2014-01-01

The main characteristic of high speed steels, besides maintaining high hardness at room temperature, is the ability of retain hardness when subjected to high temperatures and high cutting speeds. The high percentage of alloying elements in these steels allows the development of complex carbides, acquiring a high hardness by heat treatment. The aim of this study is to evaluate the effects of quenching parameters in the volumetric fraction of carbides by semi-quantitative metallography and of retained austenite by X-ray diffraction. It has been observed that, in general, the increase in the soaking time and in the austenitizing temperature resulted in the reduction of the amount of carbides and in an increase in the amount of retained austenite in the martensitic matrix. (author)

Nitrogen concentration profiles in oxy-nitrited high-speed steel

International Nuclear Information System (INIS)

Barcz, A.; Turos, A.; Wielunski, L.

1976-01-01

Nuclear microanalysis has been applied for the determination of in-depth concentration profiles of nitrogen in oxy-nitrided high-speed steel. The concentration profiles were deduced from measurements of the nitrogen content, determined by means of the 14 N(d,α) 12 C reaction for the set of initially identical samples after the removal of surface layers of sequentially increasing thicknesses. The 1.2 MeV deuterons were obtained from the Institute of Nuclear Research Van de Graaf accelerator LECH. The α-particles produced in the 14 N(d,α) 12 C reaction were detected by means of silicon surface barrier detector mounted at 150 deg C. Strong blocking of the nitrogen diffusion due to the presence of oxygen has been observed. The accuracy of nitrogen detection is of the order of 5% for nitrogen-rich regions and 10% for the matrix. However, the local non-uniformity of the steel may cause a spread of about 20% of the measured values. (T.G.)

High speed metal removal

Science.gov (United States)

Pugh, R. F.; Pohl, R. F.

1982-10-01

Four types of steel (AISI 1340, 4140, 4340, and HF-1) which are commonly used in large caliber projectile manufacture were machined at different hardness ranges representing the as-forged and the heat treated condition with various ceramic tools using ceramic coated tungsten carbide as a reference. Results show that machining speeds can be increased significantly using present available tooling.

Tool wear of (Ti, Al) N-coated polycrystalline cubic boron nitride compact in cutting of hardened steel

Science.gov (United States)

Wada, Tadahiro; Hanyu, Hiroyuki

2017-11-01

Polycrystalline cubic boron nitride compact (cBN) is effective tool material for cutting hardened steel. In addition to coated high speed steel and coated cemented carbide that has long been used for cutting materials, more recently, coated cBN has also been used. In this study, to verify the effectiveness of the (Ti,Al)N-coated cBN, which is formed on the substrate of cBN by the physical vapor deposition method, the hardened steel was turned with the (Ti,Al)N-coated cBN tool at a cutting speed of 3.33, 5.00 m/s, a feed rate of 0.3 mm/rev and a depth of cut of 0.1 mm. Furthermore, the uncoated cBN, which was the substrate of the (Ti,Al)N-coated, was also used. The tool wear of the cBN tools was experimentally investigated. The following results were obtained: (1) The contact area between the rake face and the chip of the (Ti,.Al)N-coated cBN tool was smaller than that of the uncoated cBN tool. (2) The tool wear of the (Ti,Al)N-coated cBN was smaller than that of uncoated cBN. (3) The wear progress of the (Ti,Al)N-coated cBN with the main element phase of the TiCN-Al, was slower than that of the (Ti,Al)N-coated cBN with the main element phase of the TiN-Al. (4) In the case of the high cutting speed of 5.00 m/s, the tool wear of the (Ti,Al)N-coated cBN was also smaller than that of uncoated cBN. The above results clarify that the (Ti,Al)N-coated cBN can be used as a tool material in high feed cutting of hardened steel.

Fatigue crack Behaviour in a High Strength Tool Steel

DEFF Research Database (Denmark)

Højerslev, Christian; Carstensen, Jesper V.; Brøndsted, Povl

2002-01-01

The influence of microstructure on fatigue crack initiation and crack growth of a hardened and tempered high speed steel was investigated. The evolution of fatigue cracks was followed in four point bending at room temperature. It was found that a carbide damage zone exists above a threshold load...... value of maximally 80% of the yield strength of the steel. The size of this carbide damage zone increases with increasing load amplitude, and the zone is apparently associated with crack nucleation. On fatigue crack propagation plastic deformation of the matrix occurs in a radius of approximately 4...... microns in front of the fatigue crack tip, which is comparable with the relevant mean free carbide spacing....

Study on Surface Integrity of AISI 1045 Carbon Steel when machined by Carbide Cutting Tool under wet conditions

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Tamin N. Fauzi

2017-01-01

Full Text Available This paper presents the evaluation of surface roughness and roughness profiles when machining carbon steel under wet conditions with low and high cutting speeds. The workpiece materials and cutting tools selected in this research were AISI 1045 carbon steel and canela carbide inserts graded PM25, respectively. The cutting tools undergo machining tests by CNC turning operations and their performances were evaluated by their surface roughness value and observation of the surface roughness profile. The machining tests were held at varied cutting speeds of 35 to 53 m/min, feed rate of 0.15 to 0.50 mm/rev and a constant depth of cut of 1 mm. From the analysis, it was found that surface roughness increased as the feed rate increased. Varian of surface roughness was suspected due to interaction between cutting speeds and feed rates as well as nose radius conditions; whether from tool wear or the formation of a built-up edge. This study helps us understand the effect of cutting speed and feed rate on surface integrity, when machining AISI 1045 carbon steel using carbide cutting tools, under wet cutting conditions.

Control over Coating Structure during Electromagnetic Welding and Application of HighSpeed Steel Powder

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L. M. Kozhuro

2004-01-01

Full Text Available The paper considers peculiar features concerning coating formation in the process of electromagnetic welding of high-speed steel powder. The paper reveals how to control coating structure that ensures the required operational properties of working surfaces of machine parts. 

RESEARCH OF INFLUENCE OF THE HIGH-SPEED THERMAL PROCESSING REGIMES ON STRUCTURE AND MECHANICAL PROPERTIES OF PIPE STEEL 32G2

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A. I. Gordienko

2012-01-01

Full Text Available Researches on influence of high-speed heating temperature, regimes of cooling and temperature of abatement on structure and mechanical properties of pipe steel 32G2 are carried out. Recommendations on the regimes of high-speed thermal processing of steel 32G2 which can be used at manufacturing of seamless pipes are given.

Reduced activation ODS ferritic steel - recent development in high speed hot extrusion processing

Energy Technology Data Exchange (ETDEWEB)

Oksiuta, Zbigniew [Faculty of Mechanical Engineering, Bialystok Technical University (Poland); Lewandowska, Malgorzata; Kurzydlowski, Krzysztof [Faculty of Materials Science and Engineering, Warsaw University of Technology (Poland); Baluc, Nadine [Ecole Polytechnique Federale de Lausanne (EPFL), Centre de Recherches en Physique des Plasmas, Association Euratom-Confederation Suisse, Villigen PSI (Switzerland)

2010-05-15

The paper presents the microstructure and mechanical properties of an oxide dispersion strengthened (ODS), reduced activation, ferritic steel, namely the Fe-14Cr-2W-0.3Ti-0.3Y{sub 2}O{sub 3} alloy, which was fabricated by hot isostatic pressing followed by high speed hydrostatic extrusion (HSHE) and heat treatment HT at 1050 C. Transmission electron microscopy (TEM) observations revealed significant differences in the grain size and dislocation density between the as-HIPped and as-HSHE materials. It was also found that the microstructure of the steel is stable after HT. The HSHE process improves significantly the tensile and Charpy impact properties of the as-HIPped steel. The ultimate tensile strength at room temperature increases from 950 up to 1350 MPa, while the upper shelf energy increases from 3.0 up to 6.0 J. However, the ductile-to-brittle transition temperature (DBTT) remains relatively high (about 75 C).These results indicate that HSHE is a promising method for achieving grain refinement and thus improving the mechanical properties of ODS ferritic steels. (Abstract Copyright [2010], Wiley Periodicals, Inc.)

Tool wear analysis during duplex stainless steel trochoidal milling

Science.gov (United States)

Amaro, Paulo; Ferreira, Pedro; Simões, Fernando

2018-05-01

In this study a tool with interchangeable inserts of sintered carbides coated with AlTiN were used to mill a duplex stainless steel with trochoidal strategies. Cutting speed range from 120 to 300 m/min were used and t he evaluation of tool deterioration and tool life was made according international standard ISO 8688-1. It was observed a progressive development of a flank wear and a cumulative cyclic process of localized adhesion of the chip to the cutting edge, followed by chipping, loss of the coating and substrate exposure. The tool life reached a maximum of 35 min. for cutting speed of 120 m/min. However, it was possible to maintain a tool life of 20-25 minutes when the cutting speed was increased up to 240 m/min.

Tool steels

DEFF Research Database (Denmark)

Højerslev, C.

2001-01-01

On designing a tool steel, its composition and heat treatment parameters are chosen to provide a hardened and tempered martensitic matrix in which carbides are evenly distributed. In this condition the matrix has an optimum combination of hardness andtoughness, the primary carbides provide...... resistance against abrasive wear and secondary carbides (if any) increase the resistance against plastic deformation. Tool steels are alloyed with carbide forming elements (Typically: vanadium, tungsten, molybdenumand chromium) furthermore some steel types contains cobalt. Addition of alloying elements...... serves primarily two purpose (i) to improve the hardenabillity and (ii) to provide harder and thermally more stable carbides than cementite. Assuming proper heattreatment, the properties of a tool steel depends on the which alloying elements are added and their respective concentrations....

Study of the solidification of M2 high speed steel Laser Cladding coatings

Directory of Open Access Journals (Sweden)

Candel, J. J.

2013-10-01

Full Text Available High speed steel laser cladding coatings are complex because cracks appear and the hardness is lower than expected. In this paper AISI M2 tool steel coatings on medium carbon AISI 1045 steel substrate have been manufactured and after Laser Cladding (LC processing it has been applied a tempering heat treatment to reduce the amount of retained austenite and to precipitate secondary carbides. The study of metallurgical transformations by Scanning Electron Microscopy (SEM and Electron Back Scattered Diffraction (EBSD shows that the microstructure is extremely fine and complex, with eutectic transformations and MC, M2C and M6C precipitation. Therefore, after the laser coating is necessary to use post-weld heat treatments.Los recubrimientos de acero rápido por Laser Cladding (LC son complejos porque aparecen fisuras y la dureza es menor a la esperada. En este trabajo se han fabricado recubrimientos de acero AISI M2 sobre acero al carbono AISI 1045 y tras el procesado por láser, se han revenido para reducir la cantidad de austenita retenida y precipitar carburos secundarios. El estudio de las transformaciones metalúrgicas con Microscopía Electrónica de Barrido (MEB y Difracción de Electrones Retrodispersados (EBSD muestra que la microestructura es extremadamente fina y compleja, presenta transformaciones eutécticas y precipitación de carburos MC, M2C y M6C. Por tanto, tras el recubrimiento por láser es necesario recurrir a tratamientos térmicos post-soldeo.

Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

Directory of Open Access Journals (Sweden)

Okokpujie Imhade Princess

2017-12-01

Full Text Available In recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N, feed rate (f, axial depth of cut (a and radial depth of cut (r. The experiment was designed using central composite design (CCD in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM. The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

Science.gov (United States)

Okokpujie, Imhade Princess; Ikumapayi, Omolayo M.; Okonkwo, Ugochukwu C.; Salawu, Enesi Y.; Afolalu, Sunday A.; Dirisu, Joseph O.; Nwoke, Obinna N.; Ajayi, Oluseyi O.

2017-12-01

In recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

The influence of drawing speed on surface topography of high carbon steel wires

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M. Suliga

2017-01-01

Full Text Available In this work the influence of the drawing speed on surface topography of high carbon steel wires has been assessed. The drawing process of f 5,5 mm wire rod to the final wire of f 1,7 mm was conducted in 12 passes by means of a modern Koch multi-die drawing machine. The drawing speeds in the last passes were: 5, 10, 15, 20 and 25 m/s. For final wires f 1,7 mm the three-dimensional analysis of the wire surface topography investigation was determined. It has been proved that the wire topography in the drawing process is characterized by a random anisotropy and the amount of directing the geometrical structure of the surface depends on the drawing speed.

Surface enhancement of cold work tool steels by friction stir processing with a pinless tool

Science.gov (United States)

Costa, M. I.; Verdera, D.; Vieira, M. T.; Rodrigues, D. M.

2014-03-01

The microstructure and mechanical properties of enhanced tool steel (AISI D2) surfaces produced using a friction stir welding (FSW) related procedure, called friction stir processing (FSP), are analysed in this work. The surface of the tool steel samples was processed using a WC-Co pinless tool and varying processing conditions. Microstructural analysis revealed that meanwhile the original substrate structure consisted of a heterogeneous distribution of coarse carbides in a ferritic matrix, the transformed surfaces consisted of very small carbides, homogenously distributed in a ferrite- bainite- martensite matrix. The morphology of the surfaces, as well as its mechanical properties, evaluated by hardness and tensile testing, were found to vary with increasing tool rotation speed. Surface hardness was drastically increased, relative to the initial hardness of bulk steel. This was attributed to ferrite and carbide refinement, as well as to martensite formation during solid state processing. At the highest rotation rates, tool sliding during processing deeply compromised the characteristics of the processed surfaces.

Wear evaluation of flank in burins of high speed steel modified with titanium ions

Science.gov (United States)

E Caballero, J.; V-Niño, E. D.

2017-12-01

This report shows the results obtained researching the flank wearing resistance performed by the high-speed steel (HSS) burins without any surface treatment (reference substrate) and others with surface treatment based on Titanium ions. The flank wearing was carried out by means of an industrial process by chip removal with repetitive tests of dry finished turning of AISI/SAE 1045 steel bars. The useful service life of the burins was evaluated according to ISO 3685:1993, and it was found that the burins treated with Titanium ions showed an increase in the flank wearing resistance with respect to the ones used as reference.

Microstructural characterisation of vacuum sintered T42 powder metallurgy high-speed steel after heat treatments

International Nuclear Information System (INIS)

Trabadelo, V.; Gimenez, S.; Iturriza, I.

2009-01-01

High-speed steel powders (T42 grade) have been uniaxially cold-pressed and vacuum sintered to full density. Subsequently, the material was heat treated following an austenitising + quenching + multitempering route or alternatively austenitising + isothermal annealing. The isothermal annealing route was designed in order to attain a hardness value of ∼50 Rockwell C (HRC) (adequate for structural applications) while the multitempering parameters were selected to obtain this value and also the maximum hardening of the material (∼66 HRC). Microstructural characterisation has been carried out by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The microstructure consists of a ferrous (martensitic or ferritic) matrix with a distribution of second phase particles corresponding to nanometric and submicrometric secondary carbides precipitated during heat treatment together with primary carbides. The identification of those secondary precipitates (mainly M 3 C, M 6 C and M 23 C 6 carbides) has allowed understanding the microstructural evolution of T42 high-speed steel under different processing conditions

Surface grinding characteristics of ferrous metals under high-speed and speed-stroke grinding conditions

International Nuclear Information System (INIS)

Ghani, A.K.; Choudhury, I.A.; Ahim, M.B.

1999-01-01

Some ferrous metals have been ground under different conditions with high-speed and speed-stroke in surface grinding operation. The paper describes experimental investigation of grinding forces in grinding some ferrous metals with the application of cutting fluids. Grinding tests have been carried out on mild steel, assab steel and stainless steel with different combinations of down feed and cross feed. The wheel speed was 27 m/sec while the table speed was maintained at the maximum possible 25 m/min. The grindability has been evaluated by measuring the grinding forces, grinding ratio, and surface finish. Grinding forces have been plotted against down feed of the grinding wheel and cross feed of the table. It has been observed that the radial and tangential grinding forces in stainless steel were higher than those in assab steel and mild steel

Influence of Tool Rotational Speed and Post-Weld Heat Treatments on Friction Stir Welded Reduced Activation Ferritic-Martensitic Steel

Science.gov (United States)

Manugula, Vijaya L.; Rajulapati, Koteswararao V.; Reddy, G. Madhusudhan; Mythili, R.; Bhanu Sankara Rao, K.

2017-08-01

The effects of tool rotational speed (200 and 700 rpm) on evolving microstructure during friction stir welding (FSW) of a reduced activation ferritic-martensitic steel (RAFMS) in the stir zone (SZ), thermo-mechanically affected zone (TMAZ), and heat-affected zone (HAZ) have been explored in detail. The influence of post-weld direct tempering (PWDT: 1033 K (760 °C)/ 90 minutes + air cooling) and post-weld normalizing and tempering (PWNT: 1253 K (980 °C)/30 minutes + air cooling + tempering 1033 K (760 °C)/90 minutes + air cooling) treatments on microstructure and mechanical properties has also been assessed. The base metal (BM) microstructure was tempered martensite comprising Cr-rich M23C6 on prior austenite grain and lath boundaries with intra-lath precipitation of V- and Ta-rich MC precipitates. The tool rotational speed exerted profound influence on evolving microstructure in SZ, TMAZ, and HAZ in the as-welded and post-weld heat-treated states. Very high proportion of prior austenitic grains and martensite lath boundaries in SZ and TMAZ in the as-welded state showed lack of strengthening precipitates, though very high hardness was recorded in SZ irrespective of the tool speed. Very fine-needle-like Fe3C precipitates were found at both the rotational speeds in SZ. The Fe3C was dissolved and fresh precipitation of strengthening precipitates occurred on both prior austenite grain and sub-grain boundaries in SZ during PWNT and PWDT. The post-weld direct tempering caused coarsening and coalescence of strengthening precipitates, in both matrix and grain boundary regions of TMAZ and HAZ, which led to inhomogeneous distribution of hardness across the weld joint. The PWNT heat treatment has shown fresh precipitation of M23C6 on lath and grain boundaries and very fine V-rich MC precipitates in the intragranular regions, which is very much similar to that prevailed in BM prior to FSW. Both the PWDT and PWNT treatments caused considerable reduction in the hardness of SZ

Performance of Ti-multilayer coated tool during machining of MDN431 alloyed steel

Science.gov (United States)

Badiger, Pradeep V.; Desai, Vijay; Ramesh, M. R.

2018-04-01

Turbine forgings and other components are required to be high resistance to corrosion and oxidation because which they are highly alloyed with Ni and Cr. Midhani manufactures one of such material MDN431. It's a hard-to-machine steel with high hardness and strength. PVD coated insert provide an answer to problem with its state of art technique on the WC tool. Machinability studies is carried out on MDN431 steel using uncoated and Ti-multilayer coated WC tool insert using Taguchi optimisation technique. During the present investigation, speed (398-625rpm), feed (0.093-0.175mm/rev), and depth of cut (0.2-0.4mm) varied according to Taguchi L9 orthogonal array, subsequently cutting forces and surface roughness (Ra) were measured. Optimizations of the obtained results are done using Taguchi technique for cutting forces and surface roughness. Using Taguchi technique linear fit model regression analysis carried out for the combination of each input variable. Experimented results are compared and found the developed model is adequate which supported by proof trials. Speed, feed and depth of cut are linearly dependent on the cutting force and surface roughness for uncoated insert whereas Speed and depth of cut feed is inversely dependent in coated insert for both cutting force and surface roughness. Machined surface for coated and uncoated inserts during machining of MDN431 is studied using optical profilometer.

High speed dry machining of MMCs with diamond tools

International Nuclear Information System (INIS)

Collins, J.L.

2001-01-01

The increasing use of metal matrix composites (MMCs) has raised new issues in their machining. Industrial demands for higher speed and dry machining of MMCs with improved component production to closer tolerances have driven the development of new tool materials. In particular, the wear characteristics of synthetic diamond tooling satisfy many of the requirements imposed in cutting these highly abrasive workpieces. The use of diamond tool materials, such as polycrystalline diamond (PCD), has resulted in tool life improvements which, allied with environmental considerations, show great potential for the development of dry cutting. This paper explores the wear characteristics of PCD, which is highly suited to the dry machining of particulate silicon carbide MMCs. Also, two further diamond tool materials are evaluated - chemical vapor deposition (CVD) thick layer diamond and synthetic single crystal diamond. Their suitability for the efficient machining of high volume fraction MMC materials is shown and their potential impact an the subsequent acceptance and integration of MMCs into engineering components is discussed. (author)

Adhesion Strength of TiN Coatings at Various Ion Etching Deposited on Tool Steels Using Cathodic Arc Pvd Technique

Science.gov (United States)

Ali, Mubarak; Hamzah, Esah; Ali, Nouman

Titanium nitride (TiN) widely used as hard coating material was coated on tool steels, namely on high-speed steel (HSS) and D2 tool steel by physical vapor deposition method. The goal of this study was to examine the effect of ion etching with and without titanium (Ti) and chromium (Cr) on the adhesion strength of TiN coatings deposited on tool steels. From the scratch tester, it was observed that by increasing Ti ion etching showed an increase in adhesion strength of the deposited coatings. The coatings deposited with Cr ion etching showed poor adhesion compared with the coatings deposited with Ti ion etching. Scratch test measurements showed that the coating deposited with titanium ion etching for 16 min is the most stable coating and maintained even at the critical load of 66 N. The curve obtained via penetration depth along the scratch trace is linear in the case of HSS, whereas is slightly flexible in the case of D2 tool steel. The coatings deposited on HSS exhibit better adhesion compared with those on D2 tool steel.

Inverse Processing of Undefined Complex Shape Parts from Structural High Alloyed Tool Steel

Czech Academy of Sciences Publication Activity Database

Monková, K.; Monka, P.; Hloch, Sergej

-, č. 1 (2014), s. 1-11 ISSN 1687-8132 Institutional support: RVO:68145535 Keywords : 3D digitization * complex shape parts * high alloyed tool steel Subject RIV: JQ - Machines ; Tools Impact factor: 0.575, year: 2014 http://www.hindawi.com/journals/ame/aip/478748/

Magnetic characterization of the stator core of a high-speed motor made of an ultrathin electrical steel sheet using the magnetic property evaluation system

Directory of Open Access Journals (Sweden)

Mohachiro Oka

2018-04-01

Full Text Available Recently, the application areas for electric motors have been expanding. For instance, electric motors are used in new technologies such as rovers, drones, cars, and robots. The motor used in such machinery should be small, high-powered, highly-efficient, and high-speed. In such motors, loss at high-speed rotation must be especially minimal. Eddy-current loss in the stator core is known to increase greatly during loss at high-speed rotation of the motor. To produce an efficient high-speed motor, we are developing a stator core for a motor using an ultrathin electrical steel sheet with only a small amount of eddy-current loss. Furthermore, the magnetic property evaluation for efficient, high-speed motor stator cores that use conventional commercial frequency is insufficient. Thus, we made a new high-speed magnetic property evaluation system to evaluate the magnetic properties of the efficient high-speed motor stator core. This system was composed of high-speed A/D converters, D/A converters, and a high-speed power amplifier. In experiments, the ultrathin electrical steel sheet dramatically suppressed iron loss and, in particular, eddy-current loss. In addition, a new high-speed magnetic property evaluation system accurately evaluated the magnetic properties of the efficient high-speed motor stator core.

Magnetic characterization of the stator core of a high-speed motor made of an ultrathin electrical steel sheet using the magnetic property evaluation system

Science.gov (United States)

Oka, Mohachiro; Enokizono, Masato; Mori, Yuji; Yamazaki, Kazumasa

2018-04-01

Recently, the application areas for electric motors have been expanding. For instance, electric motors are used in new technologies such as rovers, drones, cars, and robots. The motor used in such machinery should be small, high-powered, highly-efficient, and high-speed. In such motors, loss at high-speed rotation must be especially minimal. Eddy-current loss in the stator core is known to increase greatly during loss at high-speed rotation of the motor. To produce an efficient high-speed motor, we are developing a stator core for a motor using an ultrathin electrical steel sheet with only a small amount of eddy-current loss. Furthermore, the magnetic property evaluation for efficient, high-speed motor stator cores that use conventional commercial frequency is insufficient. Thus, we made a new high-speed magnetic property evaluation system to evaluate the magnetic properties of the efficient high-speed motor stator core. This system was composed of high-speed A/D converters, D/A converters, and a high-speed power amplifier. In experiments, the ultrathin electrical steel sheet dramatically suppressed iron loss and, in particular, eddy-current loss. In addition, a new high-speed magnetic property evaluation system accurately evaluated the magnetic properties of the efficient high-speed motor stator core.

Effect of cutting edge preparation on tool performance in hard-turning of DF-3 tool steel with ceramic tools

Energy Technology Data Exchange (ETDEWEB)

Davoudinejad, A.; Noordin, M. Y. [Universiti Teknologi Malaysia, Skudai (Malaysia)

2014-11-15

This study presents an experimental investigation on turning hardened DF-3 tool steel (∼ 58HRC) with PVD-TiN coated mixed ceramic. We focused on the effect of chamfer and honed edge geometry on tool wear, tool life, cutting forces and surface finish of the machined work piece. The effects of the process parameters on performance characteristics were investigated using ANOVA. It was found that longer tool life was recorded with chamfered edge geometry at various cutting conditions. The typical damage observed as flank and crater wear for ceramic tools and abrasive wear was found as the main mechanism.The optimal cutting speed was 155 m/min, with which a tolerable tool life and volume of material removal was obtained for both edges geometry. Finer machined surface was left by chamfered tool with feeds and speeds in the range of 0.125-0.05 mm/rev and 155-210 m/min, respectively; also, cutting forces decrease with increased cutting speed. The obtained consequence of cutting forces shows that tool wear has a considerable effect on cutting forces and greater forces values recorded with honed tools.

Effect of cutting edge preparation on tool performance in hard-turning of DF-3 tool steel with ceramic tools

International Nuclear Information System (INIS)

Davoudinejad, A.; Noordin, M. Y.

2014-01-01

This study presents an experimental investigation on turning hardened DF-3 tool steel (∼ 58HRC) with PVD-TiN coated mixed ceramic. We focused on the effect of chamfer and honed edge geometry on tool wear, tool life, cutting forces and surface finish of the machined work piece. The effects of the process parameters on performance characteristics were investigated using ANOVA. It was found that longer tool life was recorded with chamfered edge geometry at various cutting conditions. The typical damage observed as flank and crater wear for ceramic tools and abrasive wear was found as the main mechanism.The optimal cutting speed was 155 m/min, with which a tolerable tool life and volume of material removal was obtained for both edges geometry. Finer machined surface was left by chamfered tool with feeds and speeds in the range of 0.125-0.05 mm/rev and 155-210 m/min, respectively; also, cutting forces decrease with increased cutting speed. The obtained consequence of cutting forces shows that tool wear has a considerable effect on cutting forces and greater forces values recorded with honed tools.

Response Surface Methodology Approach on Effect of Cutting Parameter on Tool Wear during End Milling of High Thermal Conductivity Steel -150 (HTCS-150)

International Nuclear Information System (INIS)

Mohd Hadzley, A B; Wan Mohd Azahar, W M Y; Izamshah, R; Mohd Shahir, K; Mohd Amran, A; Anis Afuza, A

2016-01-01

This paper presents a study of development the tool life's mathematical model during the milling process on High Thermal Conductivity Steel 150 (HTCS-150) 56 HRC. Using response surface methodology, the mathematical models for tool life have been developed in terms of cutting speed, feed rate and depth of cut. Box-Behnken techniques is a part of Response Surface Methodology (RSM) has been used to carry out the work plan to predict, the tool wear and generate the numerical equation in relation to independent variable parameters by Design Expert software. Dry milling experiments were conducted by using two levels of cutting speed, feed rate and depth of cut. In this study, the variable for the cutting speed, feed rate and depth of cut were in the range of 484-553 m/min, 0.31-0.36 mm/tooth, and 0.1-0.5 mm, width of cut is constantly 0.01mm per passes. The tool wear was measured using tool maker microscope. The effect of input factors that on the responds were identified by using mean of ANOVA. The responds of tool wear then simultaneously optimized. The validation of the test reveals the model accuracy 5% and low tool wear under same experimental condition. (paper)

Response Surface Methodology Approach on Effect of Cutting Parameter on Tool Wear during End Milling of High Thermal Conductivity Steel -150 (HTCS-150)

Science.gov (United States)

Mohd Hadzley, A. B.; Mohd Azahar, W. M. Y. Wan; Izamshah, R.; Mohd Shahir, K.; Mohd Amran, A.; Anis Afuza, A.

2016-02-01

This paper presents a study of development the tool life's mathematical model during the milling process on High Thermal Conductivity Steel 150 (HTCS-150) 56 HRC. Using response surface methodology, the mathematical models for tool life have been developed in terms of cutting speed, feed rate and depth of cut. Box-Behnken techniques is a part of Response Surface Methodology (RSM) has been used to carry out the work plan to predict, the tool wear and generate the numerical equation in relation to independent variable parameters by Design Expert software. Dry milling experiments were conducted by using two levels of cutting speed, feed rate and depth of cut. In this study, the variable for the cutting speed, feed rate and depth of cut were in the range of 484-553 m/min, 0.31-0.36 mm/tooth, and 0.1-0.5 mm, width of cut is constantly 0.01mm per passes. The tool wear was measured using tool maker microscope. The effect of input factors that on the responds were identified by using mean of ANOVA. The responds of tool wear then simultaneously optimized. The validation of the test reveals the model accuracy 5% and low tool wear under same experimental condition.

Effect of wheel speed on magnetic and mechanical properties of melt spun Fe-6.5 wt.% Si high silicon steel

Science.gov (United States)

Ouyang, Gaoyuan; Jensen, Brandt; Tang, Wei; Dennis, Kevin; Macziewski, Chad; Thimmaiah, Srinivasa; Liang, Yongfeng; Cui, Jun

2018-05-01

Fe-Si electric steel is the most widely used soft magnetic material in electric machines and transformers. Increasing the silicon content from 3.2 wt.% to 6.5 wt.% brings about large improvement in the magnetic and electrical properties. However, 6.5 wt.% silicon steel is inherited with brittleness owing to the formation of B2 and D03 ordered phase. To obtain ductility in Fe-6.5wt.% silicon steel, the ordered phase has to be bypassed with methods like rapid cooling. In present paper, the effect of cooling rate on magnetic and mechanical properties of Fe-6.5wt.% silicon steel is studied by tuning the wheel speed during melt spinning process. The cooling rate significantly alters the ordering and microstructure, and thus the mechanical and magnetic properties. X-ray diffraction data shows that D03 ordering was fully suppressed at high wheel speeds but starts to nucleate at 10m/s and below, which correlates with the increase of Young's modulus towards low wheel speeds as tested by nanoindentation. The grain sizes of the ribbons on the wheel side decrease with increasing wheel speeds, ranging from ˜100 μm at 1m/s to ˜8 μm at 30m/s, which lead to changes in coercivity.

Toolpath strategy for cutter life improvement in plunge milling of AISI H13 tool steel

Science.gov (United States)

Adesta, E. Y. T.; Avicenna; hilmy, I.; Daud, M. R. H. C.

2018-01-01

Machinability of AISI H13 tool steel is a prominent issue since the material has the characteristics of high hardenability, excellent wear resistance, and hot toughness. A method of improving cutter life of AISI H13 tool steel plunge milling by alternating the toolpath and cutting conditions is proposed. Taguchi orthogonal array with L9 (3^4) resolution will be employed with one categorical factor of toolpath strategy (TS) and three numeric factors of cutting speed (Vc), radial depth of cut (ae ), and chip load (fz ). It is expected that there are significant differences for each application of toolpath strategy and each cutting condition factor toward the cutting force and tool wear mechanism of the machining process, and medial axis transform toolpath could provide a better tool life improvement by a reduction of cutting force during machining.

Thermographic measurements of high-speed metal cutting

Science.gov (United States)

Mueller, Bernhard; Renz, Ulrich

2002-03-01

Thermographic measurements of a high-speed cutting process have been performed with an infrared camera. To realize images without motion blur the integration times were reduced to a few microseconds. Since the high tool wear influences the measured temperatures a set-up has been realized which enables small cutting lengths. Only single images have been recorded because the process is too fast to acquire a sequence of images even with the frame rate of the very fast infrared camera which has been used. To expose the camera when the rotating tool is in the middle of the camera image an experimental set-up with a light barrier and a digital delay generator with a time resolution of 1 ns has been realized. This enables a very exact triggering of the camera at the desired position of the tool in the image. Since the cutting depth is between 0.1 and 0.2 mm a high spatial resolution was also necessary which was obtained by a special close-up lens allowing a resolution of app. 45 microns. The experimental set-up will be described and infrared images and evaluated temperatures of a titanium alloy and a carbon steel will be presented for cutting speeds up to 42 m/s.

The influence of remelting parameters of the electric arc and conventional tempering on the tribological resistance of high speed steel HS 6-5-2

Directory of Open Access Journals (Sweden)

A. Dziedzic

2011-07-01

Full Text Available The present thesis depicts the results of the research of tribological high speed steel HS 6-5-2 remelted with the electric arc. Steel was remelted with different parameters. The amperage of electric arc was changed, the scanning speed was changed and the single, overlapping remeltings were used. There was also the influence of conventional tempering defined, which was conducted after remelting on the tribological resistance of hardened steel. For the previously mentioned processing variants, the intensity of tribological wear was defined and the linear wear were presented, and the friction coefficients. The type of tribological wear was also given, present during the friction, technically dry, of the hardened steel. The lower intensity of tribological wear was received for the single remelting by electric arc of 50 and 70A. Using the overlapping remeltings for the strengening of the surface layer of the high speed steel HS 6-5-2 causes the increase of the intensity of tribological wear in comparison to the steel with the single remelting. The conventional tempering leads to the decrease of the intensity of tribological wear.

Experimental investigation into effect of cutting parameters on surface integrity of hardened tool steel

Science.gov (United States)

Bashir, K.; Alkali, A. U.; Elmunafi, M. H. S.; Yusof, N. M.

2018-04-01

Recent trend in turning hardened materials have gained popularity because of its immense machinability benefits. However, several machining processes like thermal assisted machining and cryogenic machining have reveal superior machinability benefits over conventional dry turning of hardened materials. Various engineering materials have been studied. However, investigations on AISI O1 tool steel have not been widely reported. In this paper, surface finish and surface integrity dominant when hard turning AISI O1 tool steel is analysed. The study is focused on the performance of wiper coated ceramic tool with respect to surface roughness and surface integrity of hardened tool steel. Hard turned tool steel was machined at varying cutting speed of 100, 155 and 210 m/min and feed rate of 0.05, 0.125 and 0.20mm/rev. The depth of cut of 0.2mm was maintained constant throughout the machining trials. Machining was conducted using dry turning on 200E-axis CNC lathe. The experimental study revealed that the surface finish is relatively superior at higher cutting speed of 210m/min. The surface finish increases when cutting speed increases whereas surface finish is generally better at lower feed rate of 0.05mm/rev. The experimental study conducted have revealed that phenomena such as work piece vibration due to poor or improper mounting on the spindle also contributed to higher surface roughness value of 0.66Ra during turning at 0.2mm/rev. Traces of white layer was observed when viewed with optical microscope which shows evidence of cutting effects on the turned work material at feed rate of 0.2 rev/min

An innovation on high-grade CNC machines tools for B-spline curve method of high-speed interpolation arithmetic

Science.gov (United States)

Zhang, Wanjun; Gao, Shanping; Cheng, Xiyan; Zhang, Feng

2017-04-01

A novel on high-grade CNC machines tools for B Spline curve method of High-speed interpolation arithmetic is introduced. In the high-grade CNC machines tools CNC system existed the type value points is more trouble, the control precision is not strong and so on, In order to solve this problem. Through specific examples in matlab7.0 simulation result showed that that the interpolation error significantly reduced, the control precision is improved markedly, and satisfy the real-time interpolation of high speed, high accuracy requirements.

Feasibility study tool for semi-rigid joints design of high-rise buildings steel structures

Science.gov (United States)

Bagautdinov, Ruslan; Monastireva, Daria; Bodak, Irina; Potapova, Irina

2018-03-01

There are many ways to consider the final cost of the high-rise building structures and to define, which of their different variations are the most effective from different points of view. The research of Jaakko Haapio is conducted in Tampere University of Technology, which aims to develop a method that allows determining the manufacturing and installation costs of steel structures already at the tender phase while taking into account their details. This paper is aimed to make the analysis of the Feature-Based Costing Method for skeletal steel structures proposed by Jaakko Haapio. The most appropriate ways to improve the tool and to implement it in the Russian circumstances for high-rise building design are derived. Presented tool can be useful not only for the designers but, also, for the steel structures manufacturing organizations, which can help to utilize BIM technologies in the organization process and controlling on the factory.

Characterization of rapidly solidified powder of high-speed steel

Czech Academy of Sciences Publication Activity Database

Miglierini, M.; Lančok, Adriana; Kusý, M.

2009-01-01

Roč. 190, 1-3 (2009), s. 51-57 ISSN 0304-3843 R&D Projects: GA ČR GP203/07/P011 Grant - others:GA(SK) VEGA1/3190/06 Institutional research plan: CEZ:AV0Z40320502 Keywords : Rapidly solidified powder * Tool steel * Mössbauer spectroscopy Subject RIV: CA - Inorganic Chemistry Impact factor: 0.209, year: 2007

Prediction Of Tensile And Shear Strength Of Friction Surfaced Tool Steel Deposit By Using Artificial Neural Networks

Science.gov (United States)

Manzoor Hussain, M.; Pitchi Raju, V.; Kandasamy, J.; Govardhan, D.

2018-04-01

Friction surface treatment is well-established solid technology and is used for deposition, abrasion and corrosion protection coatings on rigid materials. This novel process has wide range of industrial applications, particularly in the field of reclamation and repair of damaged and worn engineering components. In this paper, we present the prediction of tensile and shear strength of friction surface treated tool steel using ANN for simulated results of friction surface treatment. This experiment was carried out to obtain tool steel coatings of low carbon steel parts by changing contribution process parameters essentially friction pressure, rotational speed and welding speed. The simulation is performed by a 33-factor design that takes into account the maximum and least limits of the experimental work performed with the 23-factor design. Neural network structures, such as the Feed Forward Neural Network (FFNN), were used to predict tensile and shear strength of tool steel sediments caused by friction.

Effect of nitrogen on the stabilization of austenite in a tungsten-molybdenum high-speed steel

International Nuclear Information System (INIS)

Popandopulo, A.N.; Zhukova, L.T.

1986-01-01

A study was made of the tendency of steels R6M5 and R6Am5 to austenite stabilization after subzero treatment and high-temperature tempering in hot-rolled bars. Data indicate that in steel R6AM5 during quenching there is almost instantaneous austenite stabilization. The data was derived from a study of phase composition (exposure from a microsection in DRON-2.0 equipment in iron K /SUB alpha/ radiation), microstructure, and hardness. The authors conclude that in view of serious difficulties in metallurgical and tool production, steel R6AM5 should be supplied only at the request of the customer

Tribological properties of high-speed steel treated by compression plasma flow

International Nuclear Information System (INIS)

Cherenda, K.K.; Uglov, V.V.; Anishchik, V.M.; Stalmashonak, A.K.; Astashinski, V.M.

2004-01-01

Full text: The investigation of tribological properties of two high-speed steels AISI M2 and AISI Tl treated by the nitrogen compression plasma flow was the main aim of this work. Two types of samples were investigated before and after quenching. The plasma flow was received in a magneto-plasma compressor. The impulse duration was ∼100 μs, the number of impulses varied in the range of 1-5, the nitrogen pressure in the chamber was 400-4000 Pa, the energy absorbed by the sample was 2-10 J/cm 2 per impulse. Tribological properties were examined by means of a tribometer TAYl under conditions of dry friction. The Vickers's microhardness was measured by a hard meter PMT3. X-ray diffraction analysis, Auger electron spectroscopy, scanning electron microscopy and energy dispersion microanalysis were used for samples characterization. The earlier conducted investigations showed that the compression plasma flow suited well for the improvement of tribological properties of iron and low-alloyed steels due to the formation of hardening nitrides in the near surface layer. It was found that in the case of high-speed steels only not quenched samples had increased hardness after treatment. The latter can be explained by the formation of hardening nitrides though the phase analysis did not clearly reveal their presence. The element composition confirmed the presence of nitrogen in the surface layer with the concentration up to 30 at. %. The treatment of quenched samples almost always resulted in the hardness decrease due to the dissolution or partial dissolution of alloying elements carbides: M 6 C, MC, M 23 C 6 . The rate of carbides dissolution increased with the growth of the energy absorbed by the sample. The treated samples showed a lower value of the friction coefficient than the untreated one. It could be explained by the formation of nitrogenous austenite which was found out by the phase analysis. At the same time the compression plasma flow strongly influenced surface

Feasibility study tool for semi-rigid joints design of high-rise buildings steel structures

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Bagautdinov Ruslan

2018-01-01

Full Text Available There are many ways to consider the final cost of the high-rise building structures and to define, which of their different variations are the most effective from different points of view. The research of Jaakko Haapio is conducted in Tampere University of Technology, which aims to develop a method that allows determining the manufacturing and installation costs of steel structures already at the tender phase while taking into account their details. This paper is aimed to make the analysis of the Feature-Based Costing Method for skeletal steel structures proposed by Jaakko Haapio. The most appropriate ways to improve the tool and to implement it in the Russian circumstances for high-rise building design are derived. Presented tool can be useful not only for the designers but, also, for the steel structures manufacturing organizations, which can help to utilize BIM technologies in the organization process and controlling on the factory.

Computer simulation of the influence of the alloying elements on secondary hardness of the high-speed steels

International Nuclear Information System (INIS)

Dobrzanski, L.A.; Sitek, W.; Zaclona, J.

2004-01-01

The paper presents the method of modelling of high-speed steels' (HSS) properties, being basing on chemical composition and heat treatment parameters, employing neural networks. An example of its application possibility the computer simulation was made of the influence of the particular alloying elements on hardness and obtained results are presented. (author)

Ultra-high surface speed for metal removal, artillery shell

Science.gov (United States)

Pugh, R. F.; Walsh, M. R.; Pohl, R. F.

1981-07-01

Four types of steel (AISI 1340, 4140, 4340, and HF-1) which are commonly used in large caliber projectile manufacture were machined with five types of tools at different hardness ranges representing the as-forged and the heat-treated condition. Results show that machining speeds can be increased significantly over current practice using the present available tooling.

Comparative study of AISI M3:2 high speed steel produced through different techniques of manufacturing; Estudo comparativo de acos rapidos AISI M3:2 produzidos por diferentes processos de fabricacao

Energy Technology Data Exchange (ETDEWEB)

Araujo Filho, Oscar Olimpio de

2006-07-01

In this work AISI M3:2 high speed steels obtained through different techniques of manufacturing, submitted to the same heat treatment procedure were evaluated by measuring their mechanical properties of transverse rupture strength and hardness. Sinter 23 obtained by hot isostatic pressing (HIP), VWM3C obtained by the conventional route and a M3:2 high speed steel obtained by cold compaction of water atomized powders and vacuum sintered with and without the addition of a small quantity of carbon were evaluated after the same heat treatment procedure. The vacuum sintered M3:2 high speed steel can be an alternative to the more expensive high speed steel produced by hot isostatic pressing and with similar properties presented by the conventional one. The characterization of the vacuum sintered M3:2 high speed steel was performed by measuring the densities of the green compacts and after the sintering cycle. The sintering produced an acceptable microstructure and densities near to the theoretical. The transverse rupture strength was evaluated by means of three point bending tests and the hardness by means of Rockwell C and Vickers tests. The technique of scanning electronic microscopy (SEM) was used to evaluate the microstructure and to establish a relation with the property of transverse rupture strength. The structure was determined by means of X-ray diffraction (XRD) patterns and the retained austenite was detected to all the conditions of heat treatment. The main contribution of this work is to establish a relation between the microstructure and the mechanical property of transverse rupture strength and to evaluate the AISI M3:2 vacuum sintered high speed steel as an alternative to the similar commercial high speed steels. (author)

Microstructural study and densification analysis of hot work tool steel matrix composites reinforced with TiB{sub 2} particles

Energy Technology Data Exchange (ETDEWEB)

Fedrizzi, A., E-mail: anna.fedrizzi@ing.unitn.it [Department of Industrial Engineering, University of Trento, Via Mesiano 77, 38123 Trento (Italy); Pellizzari, M. [Department of Industrial Engineering, University of Trento, Via Mesiano 77, 38123 Trento (Italy); Zadra, M. [K4Sint, Start-up of the University of Trento, Viale Dante 300, 38057 Pergine Valsugana (Italy); Marin, E. [Department of Chemistry, Physics and Environment, University of Udine, Via Cotonificio 108, 33100 Udine (Italy)

2013-12-15

Hot work tool steels are characterized by good toughness and high hot hardness but are less wear resistant than other tooling materials, such as high speed steel. Metal matrix composites show improved tribological behavior, but not much work has been done in the field of hot work tool steels. In this paper TiB{sub 2}-reinforced hot work tool steel matrix composites were produced by spark plasma sintering (SPS). Mechanical alloying (MA) was proposed as a suited process to improve the composite microstructure. Density measurements and microstructure confirmed that MA promotes sintering and produces a fine and homogeneous dispersion of reinforcing particles. X-ray diffraction patterns of the sintered composites highlighted the formation of equilibrium Fe{sub 2}B and TiC, as predicted by thermodynamic calculations using Thermo-Calc® software. Scanning electron microscopy as well as scanning Kelvin probe force microscopy highlighted the reaction of the steel matrix with TiB{sub 2} particles, showing the formation of a reaction layer at the TiB{sub 2}-steel interface. Phase investigations pointed out that TiB{sub 2} is not chemically stable in steel matrix because of the presence of carbon even during short time SPS. - Highlights: • TiB{sub 2} reinforced steel matrix composites were produced by spark plasma sintering. • TiB{sub 2} was successfully dispersed in the steel matrix by mechanical alloying. • Steel and TiB{sub 2} react during sintering forming equilibrium Fe{sub 2}B and TiC. • The new phases were investigated by means of AFM, Volta potential and XRD analyses.

Shock Wave Speed and Transient Response of PE Pipe with Steel-Mesh Reinforcement

Directory of Open Access Journals (Sweden)

Wuyi Wan

2016-01-01

Full Text Available A steel mesh can improve the tensile strength and stability of a polyethylene (PE pipe in a water supply pipeline system. However, it can also cause more severe water hammer hazard due to increasing wave speed. In order to analyze the influence of the steel mesh on the shock wave speed and transient response processes, an improved wave speed formula is proposed by incorporating the equivalent elastic modulus. A field measurement validates the wave speed formula. Moreover, the transient wave propagation and extreme pressures are simulated and compared by the method of characteristics (MOC for reinforced PE pipes with various steel-mesh densities. Results show that a steel mesh can significantly increase the shock wave speed in a PE pipe and thus can cause severe peak pressure and hydraulic surges in a water supply pipeline system. The proposed wave speed formula can more reasonably evaluate the wave speed and improve the transient simulation of steel-mesh-reinforced PE pipes.

Microstructure, Mechanical and Corrosion Properties of Friction Stir-Processed AISI D2 Tool Steel

Science.gov (United States)

Yasavol, Noushin; Jafari, Hassan

2015-05-01

In this study, AISI D2 tool steel underwent friction stir processing (FSP). The microstructure, mechanical properties, and corrosion resistance of the FSPed materials were then evaluated. A flat WC-Co tool was used; the rotation rate of the tool varied from 400 to 800 rpm, and the travel speed was maintained constant at 385 mm/s during the process. FSP improved mechanical properties and produced ultrafine-grained surface layers in the tool steel. Mechanical properties improvement is attributed to the homogenous distribution of two types of fine (0.2-0.3 μm) and coarse (1.6 μm) carbides in duplex ferrite-martensite matrix. In addition to the refinement of the carbides, the homogenous dispersion of the particles was found to be more effective in enhancing mechanical properties at 500 rpm tool rotation rate. The improved corrosion resistance was observed and is attributed to the volume fraction of low-angle grain boundaries produced after friction stir process of the AISI D2 steel.

Wear mechanisms in powder metallurgy high speed steels matrix composites

International Nuclear Information System (INIS)

Gordo, E.; Martinez, M. A.; Torralba, J. M.; Jimenez, J. A.

2001-01-01

The development of metal matrix composites has a major interest for automotive and cutting tools industries since they possess better mechanical properties and wear resistance than corresponding base materials. One of the manufacturing methods for these materials includes processing by powder metallurgy techniques. in this case, blending of both, base material and reinforcement powders constitute the most important process in order to achieve a homogeneous distribution of second phase particles. in the present work, composite materials of M3/2 tool steel reinforced with 2.5,5 and 8 vol% of niobium carbide have been prepared. In order to ensure a homogeneous mix, powders of both materials were mixed by dry high-energy mechanical milling at 200 r.p.m. for 40 h. After a recovering annealing, two routes for consolidate were followed die pressing and vacuum sintering, and hot isostatic pressing (HIP). Pin-on-disc tests were carried out to evaluate wear behaviour in all the materials. Results show that ceramic particles additions improve wear resistance of base material. (Author) 9 refs

Influence of deposition rate on the properties of tin coatings deposited on tool steels using arc method

International Nuclear Information System (INIS)

Akhtar, P.; Abbas, M.

2007-01-01

Titanium nitride (TiN) widely used as hard coating material, was coated on tool steels, namely on high-speed steel (HSS) and D2 tool steel by physical vapour deposition method. The study concentrated on cathodic arc physical vapour deposition (CAPVD), a technique used for the deposition of hard coatings for tooling applications, and which has many advantages. The main drawback of this technique, however, is the formation of macrodroplets (MD's) during deposition, resulting in films with rougher morphology. Various standard characterization techniques and equipment, such as electron microscopy, atomic force microscopy, hardness testing machine, scratch tester and pin-on-disc machine, were used to analyze and quantify the following properties and parameters, surface morphology, thickness, hardness, adhesion and coefficient of friction (COF) of the deposited coatings. Surface morphology revealed that the MD's produced during the etching stage, protruded through the thin film, resulting in film with deteriorated surface features. Both coating thickness and indentation loads influenced the hardness of the deposited coatings. The coatings deposited on HSS exhibit better adhesion compared to those on D2 tool steel. Standard deviation indicates that the coating deposited with thickness around 6.7 macro m showed the most stable trend of COF versus sliding distance. (author)

High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions

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José Luis Cantero

2018-03-01

Full Text Available Inconel 718 is a superalloy, considered one of the least machinable materials. Tools must withstand a high level of temperatures and pressures in a very localized area, the abrasiveness of the hard carbides contained in the Inconel 718 microstructure and the adhesion tendency during its machining. Mechanical properties along with the low thermal conductivity become an important issue for the tool wear. The finishing operations for Inconel 718 are usually performed after solution heat treatment and age hardening of the material to give the superalloy a higher level of hardness. Carbide tools, cutting fluid (at normal or high pressures and low cutting speed are the main recommendations for finish turning of Inconel 718. However, dry machining is preferable to the use of cutting fluids, because of its lower environmental impact and cost. Previous research has concluded that the elimination of cutting fluid in these processes is feasible when using hard carbide tools. Recent development of new PCBN (Polycrystalline Cubic Boron Nitride grades for cutting tools with higher tenacity has allowed the application of these tool grades in the finishing operations of Inconel 718. This work studies the performance of commercial PCBN tools from four different tool manufacturers as well as an additional grade with equivalent performance during finish turning of Inconel 718 under dry conditions. Wear tests were carried out with different cutting conditions, determining the evolution of machining forces, surface roughness and tool wear. It is concluded that it is not industrially viable the high-speed finishing of Inconel 718 in a dry environment.

High-speed micro electrode tool fabrication by a twin-wire EDM system

International Nuclear Information System (INIS)

Sheu, Dong-Yea

2008-01-01

This paper describes a new machining process which combines twin-electro-wire together with two electro discharge circuits to rapidly fabricate micro electrode tools. The results show that transistor electro discharge and RC electro discharge circuits coexist to fabricate micro tools with rough and finish machining both on the same machine. Compared to conventional wire electro discharge grinding (WEDG) technology, a twin-wire EDM system that combines rough and finish machining into one process allows the efficient fabrication of micro tools. This high-speed micro tool fabrication process can be applied not only to micro electrode machining but also to micro punching tool and micro probing tips machining

Influence of Heat Treatment on Content of the Carbide Phases in the Microstructure of High-Speed Steel

Directory of Open Access Journals (Sweden)

Jaworski J.

2017-09-01

Full Text Available This article presents the results of investigations of the effect of heat treatment temperature on the content of the carbide phase of HS3-1-2 and HS6-5-2 low-alloy high-speed steel. Analysis of the phase composition of carbides is carried out using the diffraction method. It is determined that with increasing austenitising temperature, the intensification of dissolution of M6C carbide increases. As a result, an increase in the grain size of the austenite and the amount of retained austenite causes a significant reduction in the hardness of hardened steel HS3-1-2 to be observed. The results of diffraction investigations showed that M7C3 carbides containing mainly Cr and Fe carbides and M6C carbides containing mainly Mo and W carbides are dissolved during austenitisation. During austenitisation of HS3-1-2 steel, the silicon is transferred from the matrix to carbides, thus replacing carbide-forming elements. An increase in a degree of tempering leads to intensification of carbide separation and this process reduce the grindability of tested steels.

Thixoforming of Steel: New Tools Conception to Analyse Thermal Exchanges and Strain Rate Effects

International Nuclear Information System (INIS)

Cezard, P.; Bigot, R.; Becker, E.; Mathieu, S.; Pierret, J. C.; Rassili, A.

2007-01-01

Through different papers, authors shown that the influence of thermal exchanges was a first order parameter on the semi-solid steel behaviour, and certainly for every semi-solid metallic materials. These thermal exchanges hide other parameters effect like, for example, the strain rate influence. This paper tries to determine the influence of these two parameters by using a new extrusion device on a hydraulic press. This new tools conception annihilated the influence of the decrease of the punch speed before stopping and permitted to have a constant speed during the experiment. This work also deals with the homogeneous flow during thixoforming of steel and shows the importance to couple initial temperature of the slug with punch speed. This paper presents different conditions which permitted to have a homogeneous flow by keeping a low load

Alfinated coating structure on HS6-5-2 (SW7M high speed steel

Directory of Open Access Journals (Sweden)

T. Szymczak

2010-10-01

Full Text Available The paper presents the results of immersion alfinated coating structure in AlSi5 silumin on HS6-5-2 (SW7M high speed steel. Alfinating bath temperature was 750 ± 5 ° C, time of sample immersion was τ = 180s. Thickness of obtained coating under specified conditions was g = 150μm. Manufactured coating consists of three layers of different construction phase. The first layer from the substrate „g1`” constructed with a AlFe phase consist of alloy additives constituents of HS6-5-2 (SW7M steel: W, Mo, V, Cr and Si. On it crystallizes the second layer „g1``” of AlFeWMoCr intermetallic phases also containing Si and small amount of V. Last, the outer layer „g2” of the coating is composed with silumin including AlFeWMoCrVSi intermetallic phases. Within all layers of the coating occurs carbides. Penetration of carbides to individual coating layers is mainly due to steel surface partial melting and crystallizing layers „g1`” and „g1``” by alfinating liquid and shifting into her of carbides as well as partial carbides rejection by crystallization front of intermetallic phases occurs in coating.

Modification of AISI M2 high speed tool steels after laser surface melting under different operation conditions; Modificacion de los aceros rapidos de herramientas AISI M2 por fusion superficial con laser bajo diferentes condiciones de operacion

Energy Technology Data Exchange (ETDEWEB)

Arias, J.; Cabeza, M.; Castro, G.; Feijoo, I.; Merino, P.; Pena, G.

2010-07-01

We applied a laser surface melting treatment to AISIM2 high-speed steel hardened and tempered- and studied the resulting surface characteristics (microstructure) and mechanical behavior (hardness and wear performance). The steel was treated using a Nd:YAG continuous-wave laser with different operation conditions. The influence of the laser processing parameters on the single tracks and on melted surface layer obtained by multipass system with 50% overlap were studied. The microstructure for all conditions is formed by MC- and M{sub 2}C-type carbides, martensite and retained austenite; the quantities of this phase depends on the operations conditions. It has been determined that low levels of power density and high speed scanning of the beam leads to greater homogeneity in the microstructure with high hardness values and wear resistance. (Author) 26 refs.

HIGH FREQUENCY INDUCTION WELDING OF HIGH SILICON STEEL TUBES

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Ricardo Miranda Alé

2012-06-01

Full Text Available High-Si steel is a low cost alternative for the fabrication of tubular structures resistant to atmospheric corrosion. However, the literature has often pointed out that steels presenting a higher Si content and/or a lower Mn/Si ratio have higher susceptibility to defects at the weld bond line during HFIW (High Frequency Induction Welding process, which has been widely used for manufacturing small diameter tubes. In this study the effect of the HFIW conditions on the quality of steel tubes with high-Si content and low Mn/Si ratio is investigated. The quality of welded tubes was determined by flare test and the defects in the bond line were identified by SEM. It has been found that higher welding speeds, V-convergence angles and power input should be applied in welding of high-Si steel, when compared to similar strength C-Mn steel.

Analysis of High-Power Diode Laser Heating Effects on HY-80 Steel for Laser Assisted Friction Stir Welding Applications

Energy Technology Data Exchange (ETDEWEB)

Wiechec, Maxwell; Baker, Brad; McNelley, Terry; Matthews, Manyalibo; Rubenchik, Alexander; Rotter, Mark; Beach, Ray; Wu, Sheldon

2017-01-01

In this research, several conditions of high power diode laser heated HY-80 steel were characterized to determine the viability of using such lasers as a preheating source before friction stir welding in order to reduce frictional forces thereby reducing tool wear and increasing welding speeds. Differences in microstructures within heat affected zones were identified at specific laser powers and traverse speeds. Vickers hardness values were recorded and analyzed to validate the formation of additional martensite in diode laser heated regions of HY-80 steel. Conditions that produced little to no additional martensite were identified and relationships among high power diode laser power, traverse speed, and martensite formation were determined. The development of heat affected zones, change in grain structure, and creation of additional martensite in HY-80 can be prevented through the optimization of laser amperage and transverse speed.

Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel

Science.gov (United States)

Outeiro, José C.; Umbrello, Domenico; Pina, José C.; Rizzuti, Stefania

2007-05-01

Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, the uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.

Automated Steel Cleanliness Analysis Tool (ASCAT)

Energy Technology Data Exchange (ETDEWEB)

Gary Casuccio (RJ Lee Group); Michael Potter (RJ Lee Group); Fred Schwerer (RJ Lee Group); Dr. Richard J. Fruehan (Carnegie Mellon University); Dr. Scott Story (US Steel)

2005-12-30

The objective of this study was to develop the Automated Steel Cleanliness Analysis Tool (ASCATTM) to permit steelmakers to evaluate the quality of the steel through the analysis of individual inclusions. By characterizing individual inclusions, determinations can be made as to the cleanliness of the steel. Understanding the complicating effects of inclusions in the steelmaking process and on the resulting properties of steel allows the steel producer to increase throughput, better control the process, reduce remelts, and improve the quality of the product. The ASCAT (Figure 1) is a steel-smart inclusion analysis tool developed around a customized next-generation computer controlled scanning electron microscopy (NG-CCSEM) hardware platform that permits acquisition of inclusion size and composition data at a rate never before possible in SEM-based instruments. With built-in customized ''intelligent'' software, the inclusion data is automatically sorted into clusters representing different inclusion types to define the characteristics of a particular heat (Figure 2). The ASCAT represents an innovative new tool for the collection of statistically meaningful data on inclusions, and provides a means of understanding the complicated effects of inclusions in the steel making process and on the resulting properties of steel. Research conducted by RJLG with AISI (American Iron and Steel Institute) and SMA (Steel Manufactures of America) members indicates that the ASCAT has application in high-grade bar, sheet, plate, tin products, pipes, SBQ, tire cord, welding rod, and specialty steels and alloys where control of inclusions, whether natural or engineered, are crucial to their specification for a given end-use. Example applications include castability of calcium treated steel; interstitial free (IF) degasser grade slag conditioning practice; tundish clogging and erosion minimization; degasser circulation and optimization; quality assessment/steel

Automated Steel Cleanliness Analysis Tool (ASCAT)

International Nuclear Information System (INIS)

Gary Casuccio; Michael Potter; Fred Schwerer; Richard J. Fruehan; Dr. Scott Story

2005-01-01

The objective of this study was to develop the Automated Steel Cleanliness Analysis Tool (ASCATTM) to permit steelmakers to evaluate the quality of the steel through the analysis of individual inclusions. By characterizing individual inclusions, determinations can be made as to the cleanliness of the steel. Understanding the complicating effects of inclusions in the steelmaking process and on the resulting properties of steel allows the steel producer to increase throughput, better control the process, reduce remelts, and improve the quality of the product. The ASCAT (Figure 1) is a steel-smart inclusion analysis tool developed around a customized next-generation computer controlled scanning electron microscopy (NG-CCSEM) hardware platform that permits acquisition of inclusion size and composition data at a rate never before possible in SEM-based instruments. With built-in customized ''intelligent'' software, the inclusion data is automatically sorted into clusters representing different inclusion types to define the characteristics of a particular heat (Figure 2). The ASCAT represents an innovative new tool for the collection of statistically meaningful data on inclusions, and provides a means of understanding the complicated effects of inclusions in the steel making process and on the resulting properties of steel. Research conducted by RJLG with AISI (American Iron and Steel Institute) and SMA (Steel Manufactures of America) members indicates that the ASCAT has application in high-grade bar, sheet, plate, tin products, pipes, SBQ, tire cord, welding rod, and specialty steels and alloys where control of inclusions, whether natural or engineered, are crucial to their specification for a given end-use. Example applications include castability of calcium treated steel; interstitial free (IF) degasser grade slag conditioning practice; tundish clogging and erosion minimization; degasser circulation and optimization; quality assessment/steel cleanliness; slab, billet

Laser grooving of surface cracks on hot work tool steel

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D. Klobčar

2011-10-01

Full Text Available The paper presents the analysis of laser grooving of 1.2343 tool steel hardened to 46 HRC. The effect of laser power and grooving speed on groove shape (i.e. depth and width, the material removal rate and the purity of produced groove as a measure of groove quality was investigated and analyzed using response surface methodology. Optimal parameters of laser grooving were found, which enables pure grooves suitable for laser welding.

Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels

International Nuclear Information System (INIS)

Haghshenas, M.; Abdel-Gwad, A.; Omran, A.M.; Gökçe, B.; Sahraeinejad, S.; Gerlich, A.P.

2014-01-01

Highlights: • Successful lap joints of Al 5754 sheet to coated DP600 and 22MnB5 steels. • Negligible effect of welding speed on mechanical properties of Al 5754/22MnB5 joints. • Lower strength of Al 5754/22MnB5 joints compared with Al 5754/DP600 joints. - Abstract: In the present paper friction stir-induced diffusion bonding is used for joining sheets of 5754 aluminum alloy to coated high strength steels (DP600 and 22MnB5) by promoting diffusion bonding in an overlap configuration. Mechanical performance and microstructures of joints were analyzed by overlap shear testing, metallography, and X-ray diffraction. Our results show that the strength of joint is dependent upon tool travel speed and the depth of the tool pin relative to the steel surface. The thickness and types of intermetallic compounds formed at the interface play a significant role in achieving a joint with optimum performance. That is, the formation of high aluminum composition intermetallic compounds (i.e. Al 5 Fe 2 ) at the interface of the friction stir lap joint appeared to have a more negative effect on joint strength compared to the presence of high iron composition intermetallic phases (i.e. FeAl). This is in agreement with previously reported findings that FeAl intermetallic can improve the fracture toughness and interface strength in Al/St joints

Flank wear study of coating carbides and cermet inserts during the dry high speed turning of AISI 1045 steel; Estudio del desgaste del flanco de carburos recubiertos y cermet durante el torneado de alta velocidad en seco del acero AISI 1045

Energy Technology Data Exchange (ETDEWEB)

Hernandez-Gonzalez, L. W.; Perez-Rodriguez, R.; Zambrano-Robledo, P.; Guerrero-Mata, M.; Dumitrescu, L.

2011-07-01

This work deals with the experimental study of the flank wear evolution of two coating carbide inserts and a cermet insert during the dry finishing turning of AISI 1045 steel with 400, 500 and 600 m/min cutting speeds. The results were analyzed using the variance analysis and lineal regression analysis in order to describe the relationship between the flank wear and machining time, obtaining the adjusted model equation. The investigation demonstrated a significant effect of cutting speed and machining time on the flank wear at high speed machining. The three coating layers insert showed the best performance while the two layers insert had the worst behaviour of the cutting tool wear at high cutting speeds. (Author) 19 refs.

Influence of Thickness of Multilayered Nano-Structured Coatings Ti-TiN-(TiCrAlN and Zr-ZrN-(ZrCrNbAlN on Tool Life of Metal Cutting Tools at Various Cutting Speeds

Directory of Open Access Journals (Sweden)

Alexey Vereschaka

2018-01-01

Full Text Available This paper considers the influence of thickness of multilayered nano-structured coatings Ti-TiN-(TiCrAlN and Zr-ZrN-(ZrCrNbAlN on tool life of metal cutting tools at various cutting speeds (vc = 250, 300, 350 and 400 m·min−1. The paper investigates the basic mechanical parameters of coatings and the mechanism of coating failure in scratch testing depending on thickness of coating. Cutting tests were conducted in longitudinal turning of steel C45 with tools with the coatings under study of various thicknesses (3, 5, and 7 µm, with an uncoated tool and with a tool with a “reference” coating of TiAlN. The relationship of “cutting speed vc—tool life T” was built and investigated; and the mechanisms were found to determine the selection of the optimum coating thickness at various cutting speeds. Advantages of cutting tools with these coatings are especially obvious at high cutting speeds (in particular, vc = 400 m·min−1. If at lower cutting speeds, the longest tool life is shown by tools with thicker coatings (of about 7 μm, then with an increase in cutting speed (especially at vc = 400 m·min−1 the longest tool life is shown by tools with thinner coating (of about 3 μm.

Effect of Coating Thickness on the Properties of TiN Coatings Deposited on Tool Steels Using Cathodic Arc Pvd Technique

Science.gov (United States)

Mubarak, A.; Akhter, Parvez; Hamzah, Esah; Mohd Toff, Mohd Radzi Hj.; Qazi, Ishtiaq A.

Titanium nitride (TiN) widely used as hard coating material, was coated on tool steels, namely on high-speed steel (HSS) and D2 tool steel by physical vapor deposition method. The study concentrated on cathodic arc physical vapor deposition (CAPVD), a technique used for the deposition of hard coatings for tooling applications, and which has many advantages. The main drawback of this technique, however, is the formation of macrodroplets (MDs) during deposition, resulting in films with rougher morphology. Various standard characterization techniques and equipment, such as electron microscopy, atomic force microscopy, hardness testing machine, scratch tester, and pin-on-disc machine, were used to analyze and quantify the following properties and parameters: surface morphology, thickness, hardness, adhesion, and coefficient of friction (COF) of the deposited coatings. Surface morphology revealed that the MDs produced during the etching stage, protruded through the TiN film, resulting in film with deteriorated surface features. Both coating thickness and indentation loads influenced the hardness of the deposited coatings. The coatings deposited on HSS exhibit better adhesion compared to those on D2 tool steel. Standard deviation indicates that the coating deposited with thickness around 6.7 μm showed the most stable trend of COF versus sliding distance.

Influence of cryogenic treatment on microstructure and mechanical properties of high strength AISI D2 tool steel =

Science.gov (United States)

Ghasemi Nanesa, Hadi

Cryogenic treatment, known as treating materials at sub-zero temperatures, has been added to conventional heat treatment cycle of high alloyed steels where martensitic transformation is incomplete after quenching to room temperature. Incomplete martensitic transformation occurs due to the effect of high content of alloying elements on pushing down martensite start and finish temperatures to very low values, specifically, on tool steels. In spite of obtaining significant improvements in mechanical and wear properties after cryogenic treatment, there is no cohesive picture about what exactly modifies the microstructure of tool steels during cryogenic treatment and therefore divergent opinions on the influence of process parameters are still reported. For example, the suggested time length for cryogenic treatment starts from few seconds to several days indicating the lack of understanding about micromechanisms responsible for microstructural evolution while holding at cryogenic temperatures. In this regard, the main objective of this project is to develop a better understanding on the fundamental micromechanisms operating during cryogenic treatment. To attain this objective, the following milestones are pursued. - To study the conventional cryogenic treatment and finding challenges. - To identify and characterize the optimum starting microstructure before cryogenic treatment. - To determine the important processing parameters those control the evolution of microstructure and hardness. - To investigate the interaction between carbide precipitation and martensitic transformation in the AISI D2 steel. - To propose an optimal cryogenic treatment for AISI D2 steel.

Development of Focused Ion Beam technique for high speed steel 3D-SEM artefact fabrication

DEFF Research Database (Denmark)

Carli, Lorenzo; MacDonald, A. Nicole; De Chiffre, Leonardo

2009-01-01

The work describes preliminary manufacture by grinding, followed by machining on a Focused Ion Beam (FIB), of a high speed steel step artefact for 3D-SEM calibration. The FIB is coupled with a SEM in the so called dual beam instrument. The milling capabilities of FIB were checked from a qualitative...... point of view, using the dual beam SEM imaging, and quantitatively using a reference stylus instrument, to establish traceability. A triangular section having a depth of about 10 μm was machined, where the 50 μm curvature radius due to grinding was reduced to about 2 μm by FIB milling...

Three-dimensional Finite Element Modelling of Composite Slabs for High Speed Rails

Science.gov (United States)

Mlilo, Nhlanganiso; Kaewunruen, Sakdirat

2017-12-01

Currently precast steel-concrete composite slabs are being considered on railway bridges as a viable alternative replacement for timber sleepers. However, due to their nature and the loading conditions, their behaviour is often complex. Present knowledge of the behaviour of precast steel-concrete composite slabs subjected to rail loading is limited. FEA is an important tool used to simulate real life behaviour and is widely accepted in many disciples of engineering as an alternative to experimental test methods, which are often costly and time consuming. This paper seeks to detail FEM of precast steel-concrete slabs subjected to standard in-service loading in high-speed rail with focus on the importance of accurately defining material properties, element type, mesh size, contacts, interactions and boundary conditions that will give results representative of real life behaviour. Initial finite element model show very good results, confirming the accuracy of the modelling procedure

Possibilities of Application of High Pressure Jet Assisted Machining in Hard Turning with Carbide Tools

Directory of Open Access Journals (Sweden)

G. Globočki Lakić

2017-06-01

Full Text Available High Pressure Jet Assisted Machining (HPJAM in turning is a hybrid machining method in which a high pressure jet of cooling and lubrication fluid, under high pressure (50 MPa, leads to the zone between the cutting tool edge and workpiece. An experimental study was performed to investigate the capabilities of conventional and high pressure cooling (HPC in the turning of hard-to-machine materials: hard-chromed and surface hardened steel Ck45 (58 HRc and hardened bearing steel 100Cr6 (62 HRc. Machining experiments were performed using coated carbide tools and highly cutting speed. Experimental measurements were performed for different input process parameters. The cooling capabilities are compared by monitoring of tool wear, tool life, cooling efficiency, and surface roughness. Connection between the tool wear and surface roughness is established. Experimental research show that the hard turning with carbide cutting tools and HP supply CLF provides numerous advantages from the techno-economic aspect: greater productivity, reduce of temperature in the cutting zone, improved control chip formation, extended tool life, low intensity of tool wear, surface roughness in acceptable limits, significant reduce of production costs related to the CLF.

Modelling Of Residual Stresses Induced By High Speed Milling Process

International Nuclear Information System (INIS)

Desmaison, Olivier; Mocellin, Katia; Jardin, Nicolas

2011-01-01

Maintenance processes used in heavy industries often include high speed milling operations. The reliability of the post-process material state has to be studied. Numerical simulation appears to be a very interesting way to supply an efficient residual stresses (RS) distribution prediction.Because the adiabatic shear band and the serrated chip shaping are features of the austenitic stainless steel high speed machining, a 2D high speed orthogonal cutting model is briefly presented. This finite element model, developed on Forge registered software, is based on data taken from Outeiro and al.'s paper [1]. A new behaviour law fully coupling Johnson-Cook's constitutive law and Latham and Cockcroft's damage model is detailed in this paper. It ensures results that fit those found in literature.Then, the numerical tools used on the 2D model are integrated to a 3D high speed milling model. Residual stresses distribution is analysed, on the surface and into the depth of the material. Various revolutions and passes of the two teeth hemispheric mill on the workpiece are simulated. Thus the sensitivity of the residual stresses generation to the cutting conditions can be discussed. In order to validate the 3D model, a comparison of the cutting forces measured by EDF R and D to those given by numerical simulations is achieved.

30 CFR 57.7050 - Tool and drill steel racks.

Science.gov (United States)

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Tool and drill steel racks. 57.7050 Section 57... Rotary Jet Piercing Drilling-Surface and Underground § 57.7050 Tool and drill steel racks. Receptacles or racks shall be provided for drill steel and tools stored or carried on drills. ...

Investigation of surface roughness and tool wear length with varying combination of depth of cut and feed rate of Aluminium alloy and P20 steel machining

International Nuclear Information System (INIS)

Varmma Suparmaniam, Madan; Yusoff, Ahmad Razlan

2016-01-01

High-speed milling technique is often used in many industries to boost productivity of the manufacturing of high-technology components. The occurrence of wear highly limits the efficiency and accuracy of high- speed milling operations. In this paper, analysis of high-speed milling process parameters such as material removal rate, cutting speed, feed rate and depth of cut carried out by implemented to conventional milling. This experiment investigate the effects of varying combination of depth of cut and feed rate to tool wear rate length using metallurgical microscope and surface roughness using portable surface roughness tester after end milling of Aluminium and P20 steel. Results showed that feed rate significantly influences the surface roughness value while depth of cut does not as the surface roughness value keep increasing with the increase of feed rate and decreasing depth of cut. Whereas, tool wear rate almost remain unchanged indicates that material removal rate strongly contribute the wear rate. It believe that with no significant tool wear rate the results of this experiment are useful by showing that HSM technique is possible to be applied in conventional machine with extra benefits of high productivity, eliminating semi-finishing operation and reducing tool load for finishing. (paper)

Evaluation of Cutting Fluids in Multiple Reaming of Stainless Steel

DEFF Research Database (Denmark)

Belluco, Walter; Zeng, Z.; De Chiffre, Leonardo

2001-01-01

subsequent reaming operations were carried out on austenitic stainless steel using high-speed-steel and solid carbide tools. The tested fluids were all significantly different from the reference fluid in at least some of the tested conditions. Significant differences down to 2 percent in cutting forces and 6...

Microstructural investigation of D2 tool steel during rapid solidification

Science.gov (United States)

Delshad Khatibi, Pooya

Solidification is considered as a key processing step in developing the microstructure of most metallic materials. It is, therefore, important that the solidification process can be designed and controlled in such a way so as to obtain the desirable properties in the final product. Rapid solidification refers to the system's high undercooling and high cooling rate, which can yield a microstructure with unique chemical composition and mechanical properties. An area of interest in rapid solidification application is high-chromium, high-carbon tool steels which experience considerable segregation of alloying elements during their solidification in a casting process. In this dissertation, the effect of rapid solidification (undercooling and cooling rate) of D2 tool steel on the microstructure and carbide precipitation during annealing was explored. A methodology is described to estimate the eutectic and primary phase undercooling of solidifying droplets. The estimate of primary phase undercooling was confirmed using an online measurement device that measured the radiation energy of the droplets. The results showed that with increasing primary phase and eutectic undercooling and higher cooling rate, the amount of supersaturation of alloying element in metastable retained austenite phase also increases. In the case of powders, the optimum hardness after heat treatment is achieved at different temperatures for constant periods of time. Higher supersaturation of austenite results in obtaining secondary hardness at higher annealing temperature. D2 steel ingots generated using spray deposition have high eutectic undercooling and, as a result, high supersaturation of alloying elements. This can yield near net shape D2 tool steel components with good mechanical properties (specifically hardness). The data developed in this work would assist in better understanding and development of near net shape D2 steel spray deposit products with good mechanical properties.

Effect of rotation speed and welding speed on Friction Stir Welding of AA1100 Aluminium alloy

Science.gov (United States)

Raja, P.; Bojanampati, S.; Karthikeyan, R.; Ganithi, R.

2018-04-01

Aluminum AA1100 is the most widely used grade of Aluminium due to its excellent corrosion resistance, high ductility and reflective finish, the selected material was welded with Friction Stir Welding (FSW) process on a CNC machine, using a combination of different tool rotation speed (1500 rpm, 2500 rpm, 3500 rpm) and welding speed (10 mm/min, 30 mm/min, 50 mm/min) as welding parameters. The effect of FSW using this welding parameter was studied by measuring the ultimate tensile strength of the welded joints. A high-speed steel tool was prepared for welding the Aluminium AA1100 alloy having an 8mm shoulder diameter and pin dimension of 4mm diameter and 2.8 mm length. The welded joints were tested using the universal testing machine. It was found that Ultimate Tensile Strength of FSW specimen was highest with a value of 98.08 MPa when the weld was performed at rotation speed of 1500 RPM and welding speed of 50 mm/min.

Nanocrystalline Ni-Co Alloy Synthesis by High Speed Electrodeposition

OpenAIRE

Idris, Jamaliah; Christian, Chukwuekezie; Gaius, Eyu

2013-01-01

Electrodeposition of nanocrystals is economically and technologically viable production path for the synthesis of pure metals and alloys both in coatings and bulk form. The study presents nanocrystalline Ni-Co alloy synthesis by high speed electrodeposition. Nanocrystalline Ni-Co alloys coatings were prepared by direct current (DC) and deposited directly on steel and aluminum substrates without any pretreatment, using high speed electrodeposition method. The influence of the electrolysis par...

High-throughput machining using a high-average power ultrashort pulse laser and high-speed polygon scanner

Science.gov (United States)

Schille, Joerg; Schneider, Lutz; Streek, André; Kloetzer, Sascha; Loeschner, Udo

2016-09-01

High-throughput ultrashort pulse laser machining is investigated on various industrial grade metals (aluminum, copper, and stainless steel) and Al2O3 ceramic at unprecedented processing speeds. This is achieved by using a high-average power picosecond laser in conjunction with a unique, in-house developed polygon mirror-based biaxial scanning system. Therefore, different concepts of polygon scanners are engineered and tested to find the best architecture for high-speed and precision laser beam scanning. In order to identify the optimum conditions for efficient processing when using high-average laser powers, the depths of cavities made in the samples by varying the processing parameter settings are analyzed and, from the results obtained, the characteristic removal values are specified. For overlapping pulses of optimum fluence, the removal rate is as high as 27.8 mm3/min for aluminum, 21.4 mm3/min for copper, 15.3 mm3/min for stainless steel, and 129.1 mm3/min for Al2O3, when a laser beam of 187 W average laser powers irradiates. On stainless steel, it is demonstrated that the removal rate increases to 23.3 mm3/min when the laser beam is very fast moving. This is thanks to the low pulse overlap as achieved with 800 m/s beam deflection speed; thus, laser beam shielding can be avoided even when irradiating high-repetitive 20-MHz pulses.

Modern trends in increasing the quality of the steels intended for cutting and metal-working tools: I. Improvement of granule metallurgy processes

Science.gov (United States)

Belyanchikov, L. N.

2008-12-01

The following new technological processes for producing fine gas-atomized powders of tool and high-speed steels with a low content of nonmetallic inclusions are considered: the process designed by Böhler Uddeholm Powder Technology (Austria) and processes involving a heated gas. In the former process, a metal is poured from a ladle with electroslag heating, and the atomizing unit consists of three injectors. A new process of producing tools from fine powders by three-dimensional printing, i.e., so-called 3D-printing, is described.

Effect of friction stir welding speed on the microstructure and mechanical properties of a duplex stainless steel

International Nuclear Information System (INIS)

Saeid, T.; Abdollah-zadeh, A.; Assadi, H.; Malek Ghaini, F.

2008-01-01

The present study focuses on the effect of the welding speed on the microstructure and mechanical properties of the stir zone (SZ) in friction stir welding (FSW) of SAF 2205 duplex stainless steel. A single tool, made of a WC-base material, was used to weld 2 mm-thick plates at a constant rotational speed of 600 rpm. X-ray radiography revealed that sound welds were successfully obtained for the welding speeds in the range of 50-200 mm/min, whereas a groove-like defect was formed at the higher speed of 250 mm/min. Moreover, increasing the welding speed decreased the size of the α and γ grains in the SZ, and hence, improved the mean hardness value and the tensile strength of the SZ. These results are interpreted with respect to interplay between the welding speed and the peak temperature in FSW

Yonjung High-Speed Railway Bridge Assessment Using Output-Only Structural Health Monitoring Measurements under Train Speed Changing

Directory of Open Access Journals (Sweden)

Mosbeh R. Kaloop

2016-01-01

Full Text Available Yonjung Bridge is a hybrid multispan bridge that is designed to transport high-speed trains (HEMU-430X with maximum operating speed of 430 km/h. The bridge consists of simply supported prestressed concrete (PSC and composite steel girders to carry double railway tracks. The structural health monitoring system (SHM is designed and installed to investigate and assess the performance of the bridge in terms of acceleration and deformation measurements under different speeds of the passing train. The SHM measurements are investigated in both time and frequency domains; in addition, several identification models are examined to assess the performance of the bridge. The drawn conclusions show that the maximum deflection and acceleration of the bridge are within the design limits that are specified by the Korean and European codes. The parameters evaluation of the model identification depicts the quasistatic and dynamic deformations of PSC and steel girders to be different and less correlated when higher speeds of the passing trains are considered. Finally, the variation of the frequency content of the dynamic deformations of the girders is negligible when high speeds are considered.

Heat Treatment of Cr- and Cr-V ledeburitic tool steels

Directory of Open Access Journals (Sweden)

Peter Jurči

2014-11-01

Full Text Available Cr- and Cr-V ledeburitic cold work tool steels belong to the most important tool materials for large series manufacturing. To enable high production stability, the tools must be heat treated before use. This overview paper brings a comprehensive study on the heat treatment of these materials, starting from the soft annealing and finishing with the tempering. Also, it describes the impact of any step of the heat treatment on the most important structural and mechanical characteristics, like the hardness, the toughness and the wear resistance. The widely used AIS D2- steel (conventionally manufactured and Vanadis 6 (PM are used as examples in most cases.

Análisis experimental del torneado de alta velocidad del acero AISI 1045 // Experimental analysis of high speed turning of AISI 1045 steel gears

Directory of Open Access Journals (Sweden)

Luís Wilfredo Hernández‐González

2012-01-01

Full Text Available El objetivo de este trabajo es el estudio experimental de la evolución del desgaste del flanco de dosinsertos de carburo recubiertos y un cermet, durante el torneado en seco del acero AISI 1045 con 500 y600 m/min de velocidad de corte. Los resultados fueron comparados utilizando el análisis de varianza y deregresión. La investigación mostró un efecto significativo de la velocidad de corte y del tiempo demaquinado en el desgaste del flanco. El mejor desempeño fue para el carburo recubierto con tres capas,mientras que a elevada velocidad de corte el carburo con dos capas sufrió el mayor desgaste, lo cual sedebe a que cuando pierde sus recubrimientos el substrato del inserto queda desprotegido y el desgastecrece rápidamente por la extremas condiciones del mecanizado por alta velocidad. Además, se planteanrecomendaciones del tiempo de maquinado de los insertos dadas las condiciones de elaboración por altavelocidad.Palabras claves: torneado de alta velocidad, desgaste del flanco, acero AISI 1045, estudio experimental.__________________________________________________________________________AbstractThis work deals with the experimental study of the flank wear evolution of two coating carbide inserts and acermet insert during the dry turning of AISI 1045 steel with 500 and 600 m/min cutting speed. The resultswere compared using the variance and regression analysis. The investigation showed a significant effectof cutting speed and machining time on the flank wear in high speed machining. The three coating layersinsert showed the best performance while the two layers insert had the worst behaviour of the cutting toolwear at high cutting speed, this is because once the coating film is peeled off, the substrate of the insertbecomes uncovered and the wear grows rapidly due to the extreme machining conditions for high speed.Besides, the machining time recommendations of inserts for the cutting conditions at high speed areexposed.Key words: high

36 CFR 1192.175 - High-speed rail cars, monorails and systems.

Science.gov (United States)

2010-07-01

..., monorails and systems. 1192.175 Section 1192.175 Parks, Forests, and Public Property ARCHITECTURAL AND... TRANSPORTATION VEHICLES Other Vehicles and Systems § 1192.175 High-speed rail cars, monorails and systems. (a... steel-wheel-on-steel-rail technology, and monorail systems operating primarily on dedicated rail (i.e...

Materials selection for cutting tools

International Nuclear Information System (INIS)

Burkhis, Adel M.

2008-01-01

The selection of proper tool steel for a given application is a difficult task. So; the most important selection factors in choosing cutting tool materials are based on their tool material requirements, cutting tool design and service conditions which is mainly considered as functional requirements. The processability requirements concerns in heat treat ability of the material tool. The classification of these tool materials were discussed with their properties requirement and percent of alloying element which is added to give best properties with a little increase in cost that highly appear in comparison of the selection. The cutting tool materials were evaluated based on two cases; The first was in case of rough surface; the high speed steels is the best material and the other was the ceramic material is the highest performance in cutting of soft or high rate of metal removal. (author)

Effect of cutting parameters on sustainable machining performance of coated carbide tool in dry turning process of stainless steel 316

Science.gov (United States)

Bagaber, Salem A.; Yusoff, Ahmed Razlan

2017-04-01

The manufacturing industry aims to produce many products of high quality with relatively less cost and time. Different cutting parameters affect the machining performance of surface roughness, cutting force, and material removal rate. Nevertheless, a few studies reported on the effects of sustainable factors such as power consumed, cycle time during machining, and tool life on the dry turning of AISI 316. The present study aims to evaluate the machining performance of coated carbide in the machining of hard steel AISI 316 under the dry turning process. The influence of cutting parameters of cutting speed, feed rate, and depth of cut with their five (5) levels is established by a central composite design. Highly significant parameters were determined by analysis of variance (ANOVA), and the main effects of power consumed and time during machining, surface roughness, and tool wear were observed. Results showed that the cutting speed was proportional to power consumption and tool wear. Meanwhile, insignificant to surface roughness, feed rate most significantly affected surface roughness and power consumption followed by depth of cut.

Adiabatic shear bands as predictors of strain rate in high speed machining of ramax-2

International Nuclear Information System (INIS)

Zeb, M.A.; Irfan, M.A.; Velduis, A.C.

2008-01-01

Shear band formation was studied in the chips obtained by turning of stainless steel- Ramax-2 (AISI 420F). The machining was performed on a CNC lathe using a PVD (Physical Vapor Deposition) cutting tool insert. The cutting speeds ranged from 50 m/ min to 250 m/min. Dry cutting conditions were employed. At cutting speeds higher than 30 m/mill, the chip did not remain intact with the workpiece using quick stop device. It was difficult to get the chip root SEM (Scanning Electron Microscope) micrographs at further higher speeds. Therefore, the width of the shear bands was used as the predictor of the strain rates involved at various cutting speeds. The results showed that the strain rates are quite in agreement with the amount of strain rate found during machining of such types of stainless steels. It was also observed that shear band density increased with increasing cutting speed. (author)

Tool degradation during sheet metal forming of three stainless steel alloys

DEFF Research Database (Denmark)

Wadman, Boel; Nielsen, Peter Søe; Wiklund, Daniel

2010-01-01

To evaluate if changes in tool design and tool surface preparation are needed when low-Ni stainless steels are used instead of austenitic stainless steels, the effect on tool degradation in the form of galling was investigated with three different types of stainless steel. The resistance to tool ...

Spinodal decomposition in AISI 316L stainless steel via high-speed laser remelting

Energy Technology Data Exchange (ETDEWEB)

Chikarakara, Evans, E-mail: evans.chikarakara2@mail.dcu.ie [Advanced Processing Technology Research Centre, Dublin City University, Dublin (Ireland); Naher, Sumsun, E-mail: sumsun.naher@city.ac.uk [School of Engineering and Mathematical Sciences, City University London (United Kingdom); Brabazon, Dermot, E-mail: dermot.brabazon@dcu.ie [Advanced Processing Technology Research Centre, Dublin City University, Dublin (Ireland)

2014-05-01

A 1.5 kW CO{sub 2} pulsed laser was used to melt the surface of AISI 316L stainless steel with a view to enhancing the surface properties for engineering applications. A 90 μm laser beam spot size focused onto the surface was used to provide high irradiances (up to 23.56 MW/cm{sup 2}) with low residence times (as low as 50 μs) in order to induce rapid surface melting and solidification. Variations in microstructure at different points within the laser treated region were investigated. From this processing refined lamellar and nodular microstructures were produced. These sets of unique microstructures were produced within the remelted region when the highest energy densities were selected in conjunction with the lowest residence times. The transformation from the typical austenitic structure to much finer unique lamellar and nodular structures was attributed to the high thermal gradients achieved using these selected laser processing parameters. These structures resulted in unique characteristics including elimination of cracks and a reduction of inclusions within the treated region. Grain structure reorientation between the bulk alloy and laser-treated region occurred due to the induced thermal gradients. This present article reports on microstructure forms resulting from the high-speed laser surface remelting and corresponding underlying kinetics.

Effect of vanadium carbide on dry sliding wear behavior of powder metallurgy AISI M2 high speed steel processed by concentrated solar energy

Energy Technology Data Exchange (ETDEWEB)

García, C. [Materials Engineering. E.I.I., Universidad de Valladolid. C/Paseo del cauce 59, 47011 Valladolid (Spain); Romero, A. [E.T.S. Ingenieros Industriales. Instituto de Investigaciones Energéticas y Aplicaciones Industriales (INEI). Universidad de Castilla-La Mancha, Edificio Politécnico, Avda. Camilo José Cela s/n, 13071 Ciudad Real (Spain); Herranz, G., E-mail: gemma.herranz@uclm.es [E.T.S. Ingenieros Industriales. Instituto de Investigaciones Energéticas y Aplicaciones Industriales (INEI). Universidad de Castilla-La Mancha, Edificio Politécnico, Avda. Camilo José Cela s/n, 13071 Ciudad Real (Spain); Blanco, Y.; Martin, F. [Materials Engineering. E.I.I., Universidad de Valladolid. C/Paseo del cauce 59, 47011 Valladolid (Spain)

2016-11-15

Mixtures of AISI M2 high speed steel and vanadium carbide (3, 6 or 10 wt.%) were prepared by powder metallurgy and sintered by concentrated solar energy (CSE). Two different powerful solar furnaces were employed to sinter the parts and the results were compared with those obtained by conventional powder metallurgy using a tubular electric furnace. CSE allowed significant reduction of processing times and high heating rates. The wear resistance of compacts was studied by using rotating pin-on-disk and linearly reciprocating ball-on-flat methods. Wear mechanisms were investigated by means of scanning electron microscopy (SEM) observations and chemical inspections of the microstructures of the samples. Better wear properties than those obtained by conventional powder metallurgy were achieved. The refinement of the microstructure and the formation of carbonitrides were the reasons for this. - Highlights: •Powder metallurgy of mixtures of M2 high speed steel and VC are studied. •Some sintering is done by concentrated solar energy. •Rotating pin-on-disk and linearly reciprocating ball-on-flat methods are used. •The tribological properties and wear mechanisms, under dry sliding, are studied.

Study of surface integrity AISI 4140 as result of hard, dry and high speed machining using CBN

Science.gov (United States)

Ginting, B.; Sembiring, R. W.; Manurung, N.

2017-09-01

The concept of hard, dry and high speed machining can be combined, to produce high productivity, with lower production costs in manufacturing industry. Hard lathe process can be a solution to reduce production time. In lathe hard alloy steels reported problems relating to the integrity of such surface roughness, residual stress, the white layer and the surface integrity. AISI 4140 material is used for high reliable hydraulic system components. This material includes in cold work tool steel. Consideration election is because this material is able to be hardened up to 55 HRC. In this research, the experimental design using CCD model fit with three factors, each factor is composed of two levels, and six central point, experiments were conducted with 1 replications. The experimental design research using CCD model fit.

Tool Wear Analysis due to Machining In Super Austenitic Stainless Steel

Directory of Open Access Journals (Sweden)

Polishetty Ashwin

2017-01-01

Full Text Available This paper presents tool wear study when a machinability test was applied using milling on Super Austenitic Stainless Steel AL6XN alloy. Eight milling trials were performed under two cutting speeds, 100 m/min and 150 m/min, combined with two feed rates at 0.1mm/tooth and 0.15 mm/tooth and two depth of cuts at 2 mm and 3 mm. An Alicona 3D optical surface profilometer was used to scan cutting inserts flank and rake face areas for wear. Readings such as maximum and minimum deviations were extracted and used to analyse the outcomes. Results showed various types of wear were generated on the tool rake and flank faces. The common formed wear was the crater wear. The formation of the build-up edge was observed on the rake face of the cutting tool.

Influence of hot rolling and high speed hydrostatic extrusion on the microstructure and mechanical properties of RAF ODS steel

International Nuclear Information System (INIS)

Oksiuta, Z.; Kurzydlowski, K.J.; Baluc, N.

2009-01-01

Argon gas atomized, pre-alloyed Fe-14Cr-2W-0.3Ti oxide dispersion strengthened (ODS) ferritic steel powder was mechanically alloyed with 0.3Y2O3 (wt.%) nano-particles in attritor ball mill and consolidated by hot isostatic pressing (HIP) at 1150 deg. C under pressure of 200 MPa for 3 hrs. To improve mechanical properties of as HIPped ODS ingots the material was undergone further thermo-mechanical treatment (TMT), namely: hot rolling (HR) at 850 deg. C or high speed hot extrusion (HSHE) at 850 deg. C. After TMT both materials were annealed at 1050 deg. C for 1 h in vacuum. Transmission electron microscopy (TEM) observations of the ODS alloys after TMT and heat treatment exhibited elongated in a longitudinal direction grains with an average size of 75 μm. However, an equiaxed, smaller than 500 nm grains were also found in the microstructure of both materials. Different size and morphology of oxides particles were also observed. Bigger, about 150 nm Ti-Al-O particles were usually located at grain boundaries whereas Y-Ti-O nanoclusters of about 5 nm were uniformly distributed in ODS steel matrix. The Charpy impact tests revealed significantly better about 90% (5.8 J) upper shelf energy (USE) of material after HSHE but ductile to brittle transition temperature (DBTT) of both alloys was unsatisfactory. As-HR ODS steel has shown DBTT of about 55 deg. C whereas HSHE ODS steel has about 75 deg. C. This relatively high values of transition temperature were probably caused by oxides particles present at grain boundaries of the ODS alloys which decreased fracture properties of the ODS steels. High temperature tensile properties of both ODS alloys are found to be satisfactory in full range of the testing temperature from 23 up to 750 deg. C. However, about 15% better UTS and YS0.2 (1350 MPa and 1285 MPa, respectively) as well as ductility were measured in the case of the as-HSHE ODS steel. These results indicates that HSHE process of the ODS steel can be considered as more

Effect of loading speed on the stress-induced magnetic behavior of ferromagnetic steel

Energy Technology Data Exchange (ETDEWEB)

Bao, Sheng, E-mail: longtubao@zju.edu.cn; Gu, Yibin; Fu, Meili; Zhang, Da; Hu, Shengnan

2017-02-01

The primary goal of this research is to investigate the effect of loading speed on the stress-induced magnetic behavior of a ferromagnetic steel. Uniaxial tension tests on Q235 steel were carried out with various stress levels under different loading speeds. The variation of the magnetic signals surrounding the tested specimen was detected by a fluxgate magnetometer. The results indicated that the magnetic signal variations depended not only on the tensile load level but on the loading speed during the test. The magnetic field amplitude seemed to decrease gradually with the increase in loading speed at the same tensile load level. Furthermore, the evolution of the magnetic reversals is also related to the loading speed. Accordingly, the loading speed should be considered as one of the influencing variables in the Jies-Atherton model theory of the magnetomechanical effect. - Highlights: • Magnetic behaviors induced by different loading speeds were investigated. • Loading speed imposes strong impact on the variation of the magnetic field signals. • The magnetic field amplitude reduces gradually with the increasing loading speed. • The Jies-Atherton model theory should consider the effect of loading speed.

Effect of loading speed on the stress-induced magnetic behavior of ferromagnetic steel

International Nuclear Information System (INIS)

Bao, Sheng; Gu, Yibin; Fu, Meili; Zhang, Da; Hu, Shengnan

2017-01-01

The primary goal of this research is to investigate the effect of loading speed on the stress-induced magnetic behavior of a ferromagnetic steel. Uniaxial tension tests on Q235 steel were carried out with various stress levels under different loading speeds. The variation of the magnetic signals surrounding the tested specimen was detected by a fluxgate magnetometer. The results indicated that the magnetic signal variations depended not only on the tensile load level but on the loading speed during the test. The magnetic field amplitude seemed to decrease gradually with the increase in loading speed at the same tensile load level. Furthermore, the evolution of the magnetic reversals is also related to the loading speed. Accordingly, the loading speed should be considered as one of the influencing variables in the Jies-Atherton model theory of the magnetomechanical effect. - Highlights: • Magnetic behaviors induced by different loading speeds were investigated. • Loading speed imposes strong impact on the variation of the magnetic field signals. • The magnetic field amplitude reduces gradually with the increasing loading speed. • The Jies-Atherton model theory should consider the effect of loading speed.

Structural changes of carbides in a high-speed steel - M2 - after hardness and drawing back

International Nuclear Information System (INIS)

Santos, D.B.; Luz Ferreira, O. da; Ribeiro, O.L.R.

1984-01-01

The microstructure of a high-speed steel was studied through the scanning electron microscope. The carbide chemical composition was determined by the X-ray energy spectroscopy. The analyses were done in situ and in precipitate extracted from carbon replica. The phases were shown through the X-ray diffraction in the wastes from electrolytic use. In the annealed structure, some carbides as M 6 C, MC and M 23 C 6 and in the annealed and drawing back structure, carbide as M 6 C and MC were seen. The volumetric fraction of each type was calculated by quantitative metalography. The utilization of the replica technique allows the analysis of carbides smaller than 1 μm without the matrix interference. (E.G.) [pt

A comprehensive review on cold work of AISI D2 tool steel

Science.gov (United States)

Abdul Rahim, Mohd Aidil Shah bin; Minhat, Mohamad bin; Hussein, Nur Izan Syahriah Binti; Salleh, Mohd Shukor bin

2017-11-01

As a common material in mould and die application, AISI D2 cold work tool steel has proven to be a promising chosen material in the industries. However, challenges remain in using AISI D2 through a modified version with a considerable progress having been made in recent years. This paper provides a critical review of the original as-cast AISI D2 cold work tool steel up to the modified version. The main purpose is to develop an understanding of current modified tool steel trend; the machinability of AISI D2 (drilling, milling, turning, grinding and EDM/WEDM; and the microstructure evolution and mechanical properties of these cold work tool steels due to the presence of alloy materials in the steel matrix. The doping of rare earth alloy element, new steel fabrication processes, significant process parameter in machinability and surface treatment shows that there have been few empirical investigations into these cold work tool steel alloys. This study has discovered that cold work tool steel will remain to be explored in order to survive in the steel industries.

Influence of Cutting Fluid Flow Rate and Cutting Parameters on the Surface Roughness and Flank Wear of TiAlN Coated Tool In Turning AISI 1015 Steel Using Taguchi Method

Directory of Open Access Journals (Sweden)

Moganapriya C.

2017-09-01

Full Text Available This paper presents the influence of cutting parameters (Depth of cut, feed rate, spindle speed and cutting fluid flow rate on the surface roughness and flank wear of physical vapor deposition (PVD Cathodic arc evaporation coated TiAlN tungsten carbide cutting tool insert during CNC turning of AISI 1015 mild steel. Analysis of Variance has been applied to determine the critical influence of cutting parameters. Taguchi orthogonal test design has been employed to optimize the process parameters affecting surface roughness and tool wear. Depth of cut was found to be the most dominant factor contributing to high surface roughness (67.5% of the inserts. However, cutting speed, feed rate and flow rate of cutting fluid showed minimal contribution to surface roughness. On the other hand, cutting speed (45.6% and flow rate of cutting fluid (23% were the dominant factors influencing tool wear. The optimum cutting conditions for desired surface roughness constitutes the following parameters such as medium cutting speed, low feed rate, low depth of cut and high cutting fluid flow rate. Minimal tool wear was achieved for the following process parameters such as low cutting speed, low feed rate, medium depth of cut and high cutting fluid flow rate.

Synchrotron micro-diffraction analysis of the microstructure of cryogenically treated high performance tool steels prior to and after tempering

Energy Technology Data Exchange (ETDEWEB)

Xu, N.; Cavallaro, G.P. [Applied Centre for Structural and Synchrotron Studies, Mawson Lakes Blvd, University of South Australia, Mawson Lakes, South Australia 5095 (Australia); Gerson, A.R., E-mail: Andrea.Gerson@unisa.edu.au [Applied Centre for Structural and Synchrotron Studies, Mawson Lakes Blvd, University of South Australia, Mawson Lakes, South Australia 5095 (Australia)

2010-10-15

The phase transformation and strain changes within cryogenically (-196 deg. C) treated high performance tool steels (AISI H13) before and after tempering have been examined using both laboratory XRD and synchrotron micro-diffraction. The martensitic unit cell was found to have very low tetragonality as expected for low carbon steel. Tempering resulted in the diffusion of excess carbon out of the martensite phase and consequent unit cell shrinkage. In addition on tempering the martensite became more homogeneous as compared to the same samples prior to tempering. For cryogenically treated samples, the effect was most pronounced for the rapidly cooled sample which was the least homogenous sample prior to tempering but was the most homogenous sample after tempering. This suggests that the considerable degree of disorder resulting from rapid cryogenic cooling results in the beneficial release of micro-stresses on tempering thus possibly resulting in the improved wear resistance and durability observed for cryogenically treated tool steels.

Synchrotron micro-diffraction analysis of the microstructure of cryogenically treated high performance tool steels prior to and after tempering

International Nuclear Information System (INIS)

Xu, N.; Cavallaro, G.P.; Gerson, A.R.

2010-01-01

The phase transformation and strain changes within cryogenically (-196 deg. C) treated high performance tool steels (AISI H13) before and after tempering have been examined using both laboratory XRD and synchrotron micro-diffraction. The martensitic unit cell was found to have very low tetragonality as expected for low carbon steel. Tempering resulted in the diffusion of excess carbon out of the martensite phase and consequent unit cell shrinkage. In addition on tempering the martensite became more homogeneous as compared to the same samples prior to tempering. For cryogenically treated samples, the effect was most pronounced for the rapidly cooled sample which was the least homogenous sample prior to tempering but was the most homogenous sample after tempering. This suggests that the considerable degree of disorder resulting from rapid cryogenic cooling results in the beneficial release of micro-stresses on tempering thus possibly resulting in the improved wear resistance and durability observed for cryogenically treated tool steels.

Clean Cast Steel Technology, Phase IV

Energy Technology Data Exchange (ETDEWEB)

Charles E. Bates

2003-02-24

The objective of the Clean Cast Steel Technology Program was to improve casting product quality by removing or minimizing oxide defects and to allow the production of higher integrity castings for high speed machining lines. Previous research has concentrated on macro-inclusions that break, chip, or crack machine tool cutters and drills and cause immediate shutdown of the machining lines. The overall goal of the project is to reduce the amount of surface macro-inclusions and improve the machinability of steel castings. Macro-inclusions and improve the machinability of steel castings. Macro-inclusions have been identified by industrial sponsors as a major barrier to improving the quality and marketability of steel castings.

Machining tools in AISI M2 high-speed steel obtained by spray forming process; Ferramentas de usinagem em aco rapido AISI M2 obtido por conformacao por 'spray'

Energy Technology Data Exchange (ETDEWEB)

Jesus, Edilson Rosa Barbosa de. E-mail: erbjesus@usp.br

2004-07-01

The aim of the present work was the obtention of AISI M2 high-speed steel by spray forming technique and the material evaluation when used as machining tool. The obtained material was hot rolled at 50% and 72% reduction ratios, and from which it was manufactured inserts for machining tests. The performance of inserts made of the spray formed material was compared to inserts obtained from conventional and powder metallurgy (MP) processed materials. The spray formed material was chemical, physical, mechanical and microstructural characterised. For further characterisation, the materials were submitted to machining tests for performance evaluation under real work condition. The results of material characterisation highlight the potential of the spray forming technique, in the obtention of materials with good characteristics and properties. Under the current processing, hot rolling and heat treatments condition, the analysis of the results of the machining tests revealed a very similar behaviour among the tested materials. Proceeding a criterious analysis of the machining results tests, it was verified that the performance presented by the powder metallurgy material (MP) was slight superior, followed by conventional obtained material (MConv), which presented a insignificant advantage over the spray formed and hot rolled (72% reduction ratio) material. The worst result was encountered for the spray forming and hot rolled (50% reduction ratio) material that presented the highest wear values. (author)

Chip formation and surface integrity in high-speed machining of hardened steel

Science.gov (United States)

Kishawy, Hossam Eldeen A.

Increasing demands for high production rates as well as cost reduction have emphasized the potential for the industrial application of hard turning technology during the past few years. Machining instead of grinding hardened steel components reduces the machining sequence, the machining time, and the specific cutting energy. Hard turning Is characterized by the generation of high temperatures, the formation of saw toothed chips, and the high ratio of thrust to tangential cutting force components. Although a large volume of literature exists on hard turning, the change in machined surface physical properties represents a major challenge. Thus, a better understanding of the cutting mechanism in hard turning is still required. In particular, the chip formation process and the surface integrity of the machined surface are important issues which require further research. In this thesis, a mechanistic model for saw toothed chip formation is presented. This model is based on the concept of crack initiation on the free surface of the workpiece. The model presented explains the mechanism of chip formation. In addition, experimental investigation is conducted in order to study the chip morphology. The effect of process parameters, including edge preparation and tool wear on the chip morphology, is studied using Scanning Electron Microscopy (SEM). The dynamics of chip formation are also investigated. The surface integrity of the machined parts is also investigated. This investigation focusses on residual stresses as well as surface and sub-surface deformation. A three dimensional thermo-elasto-plastic finite element model is developed to predict the machining residual stresses. The effect of flank wear is introduced during the analysis. Although residual stresses have complicated origins and are introduced by many factors, in this model only the thermal and mechanical factors are considered. The finite element analysis demonstrates the significant effect of the heat generated

Microstructure and Mechanical Properties of Dissimilar Friction Stir Spot Welding Between St37 Steel and 304 Stainless Steel

Science.gov (United States)

Khodadadi, Ali; Shamanian, Morteza; Karimzadeh, Fathallah

2017-05-01

In the present study, St37 low-carbon steel and 304 stainless steel were welded successfully, with the thickness of 2 mm, by a friction stir spot welding process carried out at the tool dwell time of 6 s and two different tool rotational speeds of 630 and 1250 rpm. Metallographic examinations revealed four different zones including SZ and HAZ areas of St37 steel and SZ and TMAZ regions of 304 stainless steel in the weld nugget, except the base metals. X-ray diffraction and energy-dispersive x-ray spectroscopy experiments were used to investigate the possible formation of such phases as chromium carbide. Based on these experiments, no chromium carbide precipitation was found. The recrystallization of the weld nugget in the 304 steel and the phase transformations of the weld regions in the St37 steel enhanced the hardness of the weld joint. Hardness changes of joint were acceptable and approximately uniform, as compared to the resistance spot weld. In this research, it was also observed that the tensile/shear strength, as a crucial factor, was increased with the rise in the tool rotational speed. The bond length along the interface between metals, as an effective parameter to increase the tensile/shear strength, was also determined. At higher tool rotational speeds, the bond length was found to be improved, resulting in the tensile/shear strength of 6682 N. Finally, two fracture modes were specified through the fracture mode analysis of samples obtained from the tensile/shear test consisting of the shear fracture mode and the mixed shear/tensile fracture mode.

A study on high speed coupling design for wind turbine using a finite element analysis

Energy Technology Data Exchange (ETDEWEB)

Lee, Hyoung Woo; Kang, Jong Hun [Dept. of Mechatronics Engineering, Jungwon University, Geosan (Korea, Republic of); Han, Jeong Young [Pusan Educational Center for Computer Aided Machine Design, Pusan University, Busan (Korea, Republic of)

2016-08-15

The purpose of this study is to design a high speed coupling for 3 MW wind turbines and evaluate its structural stability. A basic analysis was performed to assess the structural stability of two materials, SPS6 steel plate and a composite material (Glass7628, Glass/Epoxy), in relation to misalignment in the axial and radial directions. The entire model was analyzed for a high speed coupling based on the SPS6 steel plate, which was found to have higher stability among the two materials, and safety factors were estimated for various levels of power delivery. To test the proposed high speed coupling design, a performance test was carried out to verify the stability of the final product.

A study on high speed coupling design for wind turbine using a finite element analysis

International Nuclear Information System (INIS)

Lee, Hyoung Woo; Kang, Jong Hun; Han, Jeong Young

2016-01-01

The purpose of this study is to design a high speed coupling for 3 MW wind turbines and evaluate its structural stability. A basic analysis was performed to assess the structural stability of two materials, SPS6 steel plate and a composite material (Glass7628, Glass/Epoxy), in relation to misalignment in the axial and radial directions. The entire model was analyzed for a high speed coupling based on the SPS6 steel plate, which was found to have higher stability among the two materials, and safety factors were estimated for various levels of power delivery. To test the proposed high speed coupling design, a performance test was carried out to verify the stability of the final product

Computer modeling design of a frame pier for a high-speed railway project

Science.gov (United States)

Shi, Jing-xian; Fan, Jiang

2018-03-01

In this paper, a double line pier on a high-speed railway in China is taken as an example. the size of each location is drawn up firstly. The design of pre-stressed steel beam for its crossbeam is carried out, and the configuration of ordinary reinforcement is carried out for concrete piers. Combined with bridge structure analysis software Midas Civil and BSAS, the frame pier is modeled and calculated. The results show that the beam and pier column section size reasonable design of pre-stressed steel beam with 17-7V5 high strength low relaxation steel strand, can meet the requirements of high speed railway carrying capacity; the main reinforcement of pier shaft with HRB400 diameter is 28mm, ring arranged around the pier, can satisfy the eccentric compression strength, stiffness and stability requirements, also meet the requirements of seismic design.

Tool life equation for blanking 18-8 stainless steel strips

International Nuclear Information System (INIS)

Faura, F.; Lopez, J.; Sanes, J.; Garcia, A.

1998-01-01

Hereinafter it is presented a model for the behaviour and life of circular blanking tool used in sheet forming processes of 18-8 stainless steel (sheet thickness: 1 mm). Frostily it has analyzed the different studies that have previously dealt with this problem. Secondly taking into account recently made experiments, it is proposed a simple formulation to predict tool life with enough reliability. to this purpose it has examined different parameters in the wear process, inferring from these the fundamental parameters that regulate them and about which the different equations have been configurated. Blanking tests were performed using a 20 t press at a speed of 150 strokes/min. Punch materials used in these test were AISI A2 and AISI D2 with diameters between 1.5 and 10 mm. The blanking tests were performed at a clearance between 5 and 20% of the work material thickness. (Author) 8 refs

Abrasive Wear Resistance of Tool Steels Evaluated by the Pin-on-Disc Testing

Science.gov (United States)

Bressan, José Divo; Schopf, Roberto Alexandre

2011-05-01

Present work examines tool steels abrasion wear resistance and the abrasion mechanisms which are one main contributor to failure of tooling in metal forming industry. Tooling used in cutting and metal forming processes without lubrication fails due to this type of wear. In the workshop and engineering practice, it is common to relate wear resistance as function of material hardness only. However, there are others parameters which influences wear such as: fracture toughness, type of crystalline structure and the occurrence of hard precipitate in the metallic matrix and also its nature. In the present investigation, the wear mechanisms acting in tool steels were analyzed and, by normalized tests, wear resistance performance of nine different types of tool steels were evaluated by pin-on-disc testing. Conventional tool steels commonly used in tooling such as AISI H13 and AISI A2 were compared in relation to tool steels fabricated by sintering process such as Crucible CPM 3V, CPM 9V and M4 steels. Friction and wear testing were carried out in a pin-on-disc automated equipment which pin was tool steel and the counter-face was a abrasive disc of silicon carbide. Normal load of 5 N, sliding velocity of 0.45 m/s, total sliding distance of 3000 m and room temperature were employed. The wear rate was calculated by the Archard's equation and from the plotted graphs of pin cumulated volume loss versus sliding distance. Specimens were appropriately heat treated by quenching and three tempering cycles. Percentage of alloying elements, metallographic analyses of microstructure and Vickers microhardness of specimens were performed, analyzed and correlated with wear rate. The work is concluded by the presentation of a rank of tool steel wear rate, comparing the different tool steel abrasion wear resistance: the best tool steel wear resistance evaluated was the Crucible CPM 9V steel.

Microstructure, composition and performance of PVD coatings designed for successful dry high speed milling

International Nuclear Information System (INIS)

Muenz, W.-D.; Lembke, M.I.; Lewis, D.B.; Smith, I.J.

2001-01-01

Dry high speed machining (HSM), particularly dry high speed milling, demands hard coatings, which exhibit high toughness, high oxidation resistance, a limited amount of residual stress and excellent adhesion to the cemented carbide (CC) substrate. These requirements are met by TiAICrYN coatings grown by the combined cathodic arc/unbalanced magnetron deposition method. Fully sufficient adhesion is achieved by ion implantation of Cr into the CC prior deposition. Residual stress is controlled by an Y - free base layer; high oxidation resistance is provided by an Y - containing 3 μm thick hard coating with 29 GPa hardness and a residual stress well below -7 GPa. Under the influence of temperatures above 800 o C, Y segregates along the columns of TiAIN and plugs the in/out diffusion of elements. A top layer of Y - containing oxynitride reduces the friction against the work piece material (0.9 to 0.65). Cutting tools coated as such may be used for dry milling up to 25 k rpm in steels HRC > 60. (author)

30 CFR 56.7050 - Tool and drill steel racks.

Science.gov (United States)

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Tool and drill steel racks. 56.7050 Section 56.7050 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL... Jet Piercing Drilling § 56.7050 Tool and drill steel racks. Receptacles or racks shall be provided for...

The influence of cooling parameters on the speed of continuous steel casting

Science.gov (United States)

Tirian, G. O.; Gheorghiu, C. A.; Hepuţ, T.; Chioncel, C. P.

2018-01-01

This paper analyzes the cooling parameters of the continuous casting speed. In the researches carried out we aimed to establish some correlation equations between the parameters characterizing the continuous casting process, the temperature of the steel at the entrance to the crystallizer, the superheating of the steel and the flow of the cooling water in the crystallizer and different zones of the secondary cooling. Parallel to these parameters were also the values for the casting speed. The research was made for the casting of round ϕ270mm semi-finished steel products. The steel was developed in an electric EBT furnace with a capacity of 100t, treated in L.F. (Ladle - Furnace) and VD (Vacuum-Degassing) and poured in a 5-wire continuous casting plant. The obtained data was processed in MATLAB using three types of correlation equations. The obtained results are presented both in the analytical and graphical form, each correlation being analyzed from the technological point of view, indicating the optimal values for the independent parameters monitored. In the analysis we present a comparison between the results obtained after the three types of equations for each correlation.

Evolution mechanisms of MgO·Al2O3 inclusions by cerium in spring steel used in fasteners of high-speed railway

International Nuclear Information System (INIS)

Wang Lijun; Wang Qi; Chou Kuochih; Liu Yanqiang

2015-01-01

The effect of rare earth metal addition on the non-metallic inclusions in spring steel used in fastener of high speed railway was investigated by metallographic examination; SEM-EDS and component analysis, aiming at deform those harmful inclusions to improve service life of spring steel. MgO·Al 2 O 3 inclusions were found in present experimental steel, which is also confirmed by the stability diagram of MgO/MgO·Al 2 O 3 /Al 2 O 3 from thermodynamic consideration. After Ce addition, the evolution process of Al 2 O 3 ·MgO inclusions was determined through the surface and line scanning. The effects of time and Ce content on the evolution of Al 2 O 3 ·MgO inclusions were examined. It was indicated that Al 2 O 3 ·MgO inclusions were wrapped by rare earth inclusions to form a ring like shape Ce-riched band around the inclusion, which would be useful to improve fatigue and corrosion resistance of spring steel. It was found that diffusion of Ce 3+ , Al 3+ and Mg 2+ in inclusions core and intermediate layer would be the limited step during evolutions of inclusions. (author)

Microstructural evolution of a cold work tool steel after pulsed laser remelting

Directory of Open Access Journals (Sweden)

L. Kosec

2012-01-01

Full Text Available The aim of this study is the investigation of micro-structural behaviour of a Mat. No. 1.2379 (EN-X160CrMoV121; AISI D2 cold work tool steel after remelting with a precise pulsed Nd:YAG laser. The investigated steel is one of the most hard to weld tool steels, due to large amount of alloying elements. The analysis was done on single spots remelted with specific laser pulse shape and parameters, assuring crack-less solidification. Re-solidifi ed areas were investigated with microscopy, hardness measurements, X-ray spectroscopy and diffraction method. Laser treatment causes rapid solidifi cation leading into a formation of a fine dendritic microstructures containing high amount of retained austenite causing a significant decrease of hardness.

Forming of High-strength Steels Using a Hot-melt Dry Lubricant

DEFF Research Database (Denmark)

Hörnström, Sven-Erik; Karlsson, Erik; Olsson, Mikael

2008-01-01

during forming resulting in seizure of the tool/steel sheet contact and extensive scratching of the steel sheet surface. As a result, a number of concepts have been developed in order to reduce the tendency to galling in metal forming, including the development of new dry lubricants, new forming tool...... steel grades and improved surface engineering treatments such as the deposition of low friction CVD and PVD coatings. In the present study the performance of a hot-melt dry lubricant in the forming of hot and cold rolled and hot-dip galvanized high strength steel has been evaluated and compared...... with a conventional rust protection oil using four different tests methods, i.e. a strip reduction test, a bending under tension test, a stretch-forming test and a pin-on disc test. In the tests, two different cold work tool steels, a conventional steel grade and a nitrogen alloyed PM steel grade were evaluated...

Development of lathe tool dynamometer and finding cutting forces using negative and positive rake angle cutting tool

International Nuclear Information System (INIS)

Zeb, M.A.; Irfan, M.A.

2005-01-01

Most output parameters in machining, such as cutting forces, temperatures, strains and the work-hardening of the chip material, are directly related to the chip formation process. The characteristics of machining processes can be well understood if the forces and strains during chip formation are known. In this research a lathe tool dynamometer was used to measure cutting forces involved in machining of Steel 1045 and Aluminum 2219 T62. High Speed Steel (HSS), cutting tools with positive and negative rake angles were used. It was observed that more cutting forces are experienced by the cutting tool with positive rake angle as compared to the forces experienced by the cutting tool with negative rake angle. For steel 1045 the cutting forces using positive rake angle cutting tool were much higher. This suggested that for harder materials using a negative rake angle is more suitable for cutting. (author)

High speed laser cutting machine. Kosoku reza kakoki

Energy Technology Data Exchange (ETDEWEB)

Shinno, N. (Matsushita Electric Industrial Co. Ltd., Kadoma, Osaka (Japan))

1993-11-01

The carbon dioxide gas laser cutting machine is being used widely for from cutting soft steel and stainless steel, etc. to intermetallic welding and in the field of cutting in particular, concerning sheet cutting, it has been changing the existing monopoly of the turret punch press, and as for medium and thick plate cutting, that of the gas plasma fusing device. This article is the general description of high speed laser cutting machine. Concerning the laser cutting (sheet cutting in particular), as the essential items for securing severe cutting accuracy and, at the same time, improving the cutting speed, the following matters are picked up for respective explanation; improvement of stationary machine accuracy, improvement of dynamic machine accuracy, improvement of quality of laser beam as well as optimization of cutting conditions, and shortening of piercing time. Also explanation is given to the respective items, namely speeding-up of medium and thick plate cutting, and reduction of load onto the operator by improved operation. Finally, feeding and removing of a sheet only, and feeding and removing with a pallet are mentioned as the efforts for automation and energy saving. 3 figs., 1 tab.

Tribological performances of new steel grades for hot stamping tools

Science.gov (United States)

Medea, F.; Venturato, G.; Ghiotti, A.; Bruschi, S.

2017-09-01

In the last years, the use of High Strength Steels (HSS) as structural parts in car body-in-white manufacturing has rapidly increased thanks to their favourable strength-to-weight ratio and stiffness, which allow a reduction of the fuel consumption to accommodate the new restricted regulations for CO2 emissions control. The survey of the technical and scientific literature shows a large interest in the development of different coatings for the blanks from the traditional Al-Si up to new Zn-based coatings and on the analysis of hard PVD, CVD coatings and plasma nitriding applied on the tools. By contrast, fewer investigations have been focused on the development and test of new tools steels grades capable to improve the wear resistance and the thermal properties that are required for the in-die quenching during forming. On this base, the paper deals with the analysis and comparison the tribological performances in terms of wear, friction and heat transfer of new tool steel grades for high-temperature applications, characterized by a higher thermal conductivity than the commonly used tools. Testing equipment, procedures as well as measurements analyses to evaluate the friction coefficient, the wear and heat transfer phenomena are presented. Emphasis is given on the physical simulation techniques that were specifically developed to reproduce the thermal and mechanical cycles on the metal sheets and dies as in the industrial practice. The reference industrial process is the direct hot stamping of the 22MnB5 HSS coated with the common Al-Si coating for automotive applications.

A temperature dependent cyclic plasticity model for hot work tool steel including particle coarsening

Science.gov (United States)

Jilg, Andreas; Seifert, Thomas

2018-05-01

Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material's yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests.

Tool steel for cold worck niobium carbides

International Nuclear Information System (INIS)

Goldenstein, H.

1984-01-01

A tool steel was designed so as to have a microstructure with the matrix similar a cold work tool steel of D series, containing a dispersion of Niobium carbides, with no intention of putting Niobium in solution on the matrix. The alloy was cast, forged and heat treated. The alloy was easily forged; the primary carbide morfology, after forging, was faceted, tending to equiaxed. The hardness obtained was equivalent to the maximum hardness of a D-3 sttel when quenched from any temperature between 950 0 C, and 1200 0 , showing a very small sensitivy to the quenching temperature. (Author) [pt

CHARACTERIZATION OF NEW TOOL STEEL FOR ALUMINUM EXTRUSION DIES

OpenAIRE

José Britti Bacalhau; Fernanda Moreno Rodrigues; Rafael Agnelli Mesquita

2014-01-01

Aluminum extrusion dies are an important segment of application on industrial tools steels, which are manufactured in steels based on AISI H13 steel. The main properties of steels applied to extrusion dies are: wear resistance, impact resistance and tempering resistance. The present work discusses the characteristics of a newly developed hot work steel to be used on aluminum extrusion dies. The effects of Cr and Mo contents with respect to tempering resistance and the Al addition ...

Experimental High Speed Milling of the Selected Thin-Walled Component

Directory of Open Access Journals (Sweden)

Jozef Zajac

2017-11-01

Full Text Available In a technical practice, it is possible to meet thin-walled parts more and more often. These parts are most commonly used in the automotive industry or aircraft industry to reduce the weight of different design part of cars or aircraft. Presented article is focused on experimental high speed milling of selected thin-walled component. The introduction of this article presents description of high speed machining and specification of thin – walled parts. The experiments were carried out using a CNC machine Pinnacle VMC 650S and C45 material - plain carbon steel for automotive components and mechanical engineering. In the last part of the article, described are the arrangements to reduction of deformation of thin-walled component during the experimental high speed milling.

Evaluation on machined surface of hardened stainless steel generated by hard turning using coated carbide tools with wiper geometry

International Nuclear Information System (INIS)

Noordin, M.Y.; Kurniawan, D.; Sharif, S.

2007-01-01

Hard turning has been explored to be the finish machining operation for parts made of hardened steel. Its feasibility is determined partially by the quality of the resulting machined surface. This study evaluates the surface integrity of martensitic stainless steel (48 HRC) resulting from hard turning using coated carbide tool with wiper geometry at various cutting speed and feed and compares to that obtained using coated carbide tool with conventional geometry. The wiper coated carbide tool is able to produce machined surface which is of finer finish (Ra is finer than 0.4 μm at most cutting parameters) and yet is similarly inducing only minor microstructural alteration compared to its conventional counterpart. From the view of the chip morphology where continuous type of chip is desired rather than sawtooth chip type, the wiper tool generates continuous chip at almost similar range of cutting parameters compared to the case when using conventional tool. Additionally, the use of wiper tool also induces the preferred compressive residual stress at the machined surface. (author)

Solidification process of a tool steel with niobium

International Nuclear Information System (INIS)

Makray, E.T.; Bresciani Filho, E.; Martinez Nazar, A.M.

1984-01-01

The solidification process of M2 high speed steel where tungsten was totally substituted by niobium was analysed. It occurs through a eutectic type reaction, in four steps. It was verified that one can apply the Coupled Zone Concept to explain the solification mechanism of this alloy: there is a primary phase (NbC), which is envolved by the other phase (ferrite) as a halo in order to send the composition back to the coupled growth region, where the binary eutectic forms. The last step is the formation of other compounds at the grain boundary. (Author) [pt

Surface characteristics analysis of dry EDMed AISI D2 steel using modified tool design

Energy Technology Data Exchange (ETDEWEB)

Pragadish, N.; Kumar, M. Pradeep [Anna University, Chennai (China)

2015-04-15

A modified tool design is proposed which helps in drilling holes without any central core, and also enables the effective removal of the debris particles. Experiments were conducted on AISI D2 Steel using copper electrode as tool in both conventional EDM and dry EDM processes and the performance of both processes is compared. Experiments were designed using Taguchi's L27 orthogonal array. Discharge current (I), gap voltage (V), pulse on time (T{sub ON}), gas pressure (P) and tool rotational speed (N) were chosen as the various input parameters, and their effect on the material removal rate (MRR), surface roughness (SR), surface morphology, microstructure and elemental composition of the machined surface is analyzed. The experimental results show better surface characteristics in the surface machined under dry EDM process.

Surface characteristics analysis of dry EDMed AISI D2 steel using modified tool design

International Nuclear Information System (INIS)

Pragadish, N.; Kumar, M. Pradeep

2015-01-01

A modified tool design is proposed which helps in drilling holes without any central core, and also enables the effective removal of the debris particles. Experiments were conducted on AISI D2 Steel using copper electrode as tool in both conventional EDM and dry EDM processes and the performance of both processes is compared. Experiments were designed using Taguchi's L27 orthogonal array. Discharge current (I), gap voltage (V), pulse on time (T ON ), gas pressure (P) and tool rotational speed (N) were chosen as the various input parameters, and their effect on the material removal rate (MRR), surface roughness (SR), surface morphology, microstructure and elemental composition of the machined surface is analyzed. The experimental results show better surface characteristics in the surface machined under dry EDM process.

High-speed motion neutron radiography

International Nuclear Information System (INIS)

Bossi, R.H.; Barton, J.P.; Robinson, A.H.

1982-01-01

A system has been developed to perform neutron radiographic analysis of dynamic events having a duration of several milliseconds. The system has been operated in the range of 2000 to 10,000 frames. Synchronization has provided high-speed motion neutron radiographs for evaluation of the firing cycles of 7.62-mm munition rounds within a thick steel rifle barrel. The system has also been used to demonstrate its ability to produce neutron radiographic movies of two-phase flow. The equipment includes a TRIGA reactor capable of pulsing to a peak power of 3000 MW, a neutron beam collimator, a scintillator neutron conversion screen coupled to an image intensifier, and a 16-mm high-speed movie camera. The peak neutron flux incident at the object position is about 4 X 10 11 n/cm 2 X s with a pulse, full-width at half-maximum, of 9 ms. Modulation transfer function techniques have been used to assist optimization of the system performance. Special studies have been performed on the scintillator conversion screens and on the effects of statistical limitations on information availability

Cadence® High High-Speed PCB Design Flow Workshop

CERN Document Server

2006-01-01

Last release of Cadence High-Speed PCB Design methodology (PE142) based on Concept-HDL schematic editor, Constraint Manager, SPECCTRAQuest signal integrity analysis tool and ALLEGRO layout associated with SPECCTRA auto router tools, is now enough developed and stable to be taken into account for high-speed board designs at CERN. The implementation of this methodology, build around the new Constraint Manager program, is essential when you have to develop a board having a lot of high-speed design rules such as terminated lines, large bus structures, maximum length, timing, crosstalk etc.. that could not be under control by traditional method. On more conventional designs, formal aspect of the methodology could avoid misunderstanding between hardware and ALLEGRO layout designers, minimizing prototype iteration, development time and price. The capability to keep trace of the original digital designer intents in schematic or board layout, loading formal constraints in EDMS, could also be considered for LHC electro...

Microstructural characterization of cermet-steel interface in rock drilling tool

International Nuclear Information System (INIS)

Ybarra, L.A.C.; Molisani, A.L.; Yoshimura, H.N.

2010-01-01

Rock drilling tools basically present a WC cermet bonded to a steel shank. The interface cermet-steel plays fundamental role during drilling operation, since the fracture of this interface is the main failure mode of the tools. In this work, the microstructure of this interface in crown samples (type A), prepared in an industrial like process, was evaluated. In this process, a WC-containing powder was infiltrated with a copper alloy at 1100 deg C in a graphite mold previously mounted with a 1020 steel tube. The powder was characterized by XRD analysis and the cross-section microstructure of cermet-steel was analyzed using SEM-EDS. It was observed that Ni and small amount of Cu from cermet matrix diffused into the superficial region of the steel, and the Cu alloy dissolved and penetrated along the steel grain boundaries, resulting in good metallurgical bonding of the interface.(author)

Micromilling of hardened tool steel for mould making applications

DEFF Research Database (Denmark)

Bissacco, Giuliano; Hansen, Hans Nørgaard; De Chiffre, Leonardo

2005-01-01

geometries as those characterizing injection moulding moulds. The realization of the micromilling process in connection with hardened tool steel as workpiece material is particularly challenging. The low strength of the miniaturized end mills implies reduction and accurate control of the chip load which...... wear. This paper presents the micromilling process applied to the manufacturing of micro injection moulding moulds in hardened tool steel, presenting experimental evidence and possible solutions to the above-mentioned issues....

Cutting characteristics and deformed layer of type 316LN stainless steel

International Nuclear Information System (INIS)

Oh, Sun Sae; Yi, Won

2004-01-01

The cutting characteristics and the deformed layer of Nitrogen(N)-added type 316LN stainless steel were comparatively investigated to type 316L stainless steel. The cutting force, the surface roughness(Ra) and the tool wear in face milling works were measured with cutting conditions, and the deformed layers were obtained from micro-hardness testing method. The cutting resistance of type 316LN was similar to type 316L in spite of its high strength. The surface roughness of type 316LN was superior to type 316L for all the cutting conditions. In particular, in the high cutting speed above 345m/min, the surface roughness of the two stainless steels was closely same. The deformed layer thickness of the two stainless steels was generated in the 150μm-300μm ranges, and its value of type 316LN was lower than that of type 316L. This is due to the high strength properties by nitrogen effect. It was found that type 316LN was higher in the tool wear than that type 316L, and flank wear was dominant to crater wear. In face milling works of type 316LN steel, tool wear is regarded as a important problem

A simple tool for tubing modification to improve spiral high-speed counter-current chromatography for protein purification.

Science.gov (United States)

Ito, Yoichiro; Ma, Xiaofeng; Clary, Robert

2016-01-01

A simple tool is introduced which can modify the shape of tubing to enhance the partition efficiency in high-speed countercurrent chromatography. It consists of a pair of interlocking identical gears, each coaxially holding a pressing wheel to intermittently compress plastic tubing in 0 - 10 mm length at every 1 cm interval. The performance of the processed tubing is examined in protein separation with 1.6 mm ID PTFE tubing intermittently pressed in 3 mm and 10 mm width both at 10 mm intervals at various flow rates and revolution speeds. A series of experiments was performed with a polymer phase system composed of polyethylene glycol and dibasic potassium phosphate each at 12.5% (w/w) in deionized water using three protein samples. Overall results clearly demonstrate that the compressed tubing can yield substantially higher peak resolution than the non-processed tubing. The simple tubing modifier is very useful for separation of proteins with high-speed countercurrent chromatography.

Thermal Error Test and Intelligent Modeling Research on the Spindle of High Speed CNC Machine Tools

Science.gov (United States)

Luo, Zhonghui; Peng, Bin; Xiao, Qijun; Bai, Lu

2018-03-01

Thermal error is the main factor affecting the accuracy of precision machining. Through experiments, this paper studies the thermal error test and intelligent modeling for the spindle of vertical high speed CNC machine tools in respect of current research focuses on thermal error of machine tool. Several testing devices for thermal error are designed, of which 7 temperature sensors are used to measure the temperature of machine tool spindle system and 2 displacement sensors are used to detect the thermal error displacement. A thermal error compensation model, which has a good ability in inversion prediction, is established by applying the principal component analysis technology, optimizing the temperature measuring points, extracting the characteristic values closely associated with the thermal error displacement, and using the artificial neural network technology.

Cutting force model for high speed machining process

International Nuclear Information System (INIS)

Haber, R. E.; Jimenez, J. E.; Jimenez, A.; Lopez-Coronado, J.

2004-01-01

This paper presents cutting force-based models able to describe a high speed machining process. The model considers the cutting force as output variable, essential for the physical processes that are taking place in high speed machining. Moreover, this paper shows the mathematical development to derive the integral-differential equations, and the algorithms implemented in MATLAB to predict the cutting force in real time MATLAB is a software tool for doing numerical computations with matrices and vectors. It can also display information graphically and includes many toolboxes for several research and applications areas. Two end mill shapes are considered (i. e. cylindrical and ball end mill) for real-time implementation of the developed algorithms. the developed models are validated in slot milling operations. The results corroborate the importance of the cutting force variable for predicting tool wear in high speed machining operations. The developed models are the starting point for future work related with vibration analysis, process stability and dimensional surface finish in high speed machining processes. (Author) 19 refs

High-speed photography. Technique and evolution

International Nuclear Information System (INIS)

Sanchez-Tembleque, R.

1981-01-01

It is intended to present some general considerations about ''Higg-speed photography'' as a tool of work common in mos research laboratories in the world. ''High-speed photography'' relies on the principles of photography of actions, that change rapidly with the time. The evolution of this technique goes along with the discovering of new phenomena in wich higher speeds are involved. At present is normal to deal with changing rates involving picoseconds times (10 -12 s) and new developments on the field of femtosecond (10 -15 s) theoretically are contemplated. (author)

Carbon and metal-carbon implantations into tool steels for improved tribological performance

Science.gov (United States)

Hirvonen, J.-P.; Harskamp, F.; Torri, P.; Willers, H.; Fusari, A.; Gibson, N.; Haupt, J.

1997-05-01

The high-fluence implantation of carbon and dual implantations of metal-metalloid pairs into steels with different microstructures are briefly reviewed. A previously unexamined system, the implantation of Si and C into two kinds of tool steels, M3 and D2, have been studied in terms of microstructure and tribological performance. In both cases ion implantation transfers a surface into an amorphous layer. However, the tribological behavior of these two materials differs remarkably: in the case of ion-implanted M3 a reduction of wear in a steel pin is observed even at high pin loads, whereas in the case of ion-implanted D2 the beneficial effects of ion implantation were limited to the lowest pin load. The importance of an initial phase at the onset of sliding is emphasized and a number of peculiarities observed in ion-implanted M3 steel are discussed.

Composite layers in the high speed steels

International Nuclear Information System (INIS)

Koson, A.; Rutkowska, A.; Dabrowski, M.

2002-01-01

The production process and different properties of TiN, (TiA)(N and TiN + (TiAl)N coatings are described in this work. The coatings were obtained on fast-cutting steel 6-5-2(SW7M) after a typical heat treatment and gas nitriding. The following features were examined: thickness and hardness of produced layers as well as wearing quality (using T-0.5 tester). Composite layer of (TiAl)N has achieved the highest wearing quality in the range of wearing parameters applied. (author)

Effect of heat treatment on the characteristics of tool steel deposited by the directed energy deposition process

Science.gov (United States)

Park, Jun Seok; Lee, Min-Gyu; Cho, Yong-Jae; Sung, Ji Hyun; Jeong, Myeong-Sik; Lee, Sang-Kon; Choi, Yong-Jin; Kim, Da Hye

2016-01-01

The directed energy deposition process has been mainly applied to re-work and the restoration of damaged steel. Differences in material properties between the base and the newly deposited materials are unavoidable, which may affect the mechanical properties and durability of the part. We investigated the effect of heat treatment on the characteristics of tool steel deposited by the DED process. We prepared general tool steel materials of H13 and D2 that were deposited onto heat-treated substrates of H13 and D2, respectively, using a direct metal tooling process. The hardness and microstructure of the deposited steel before and after heat treatment were investigated. The hardness of the deposited H13 steel was higher than that of wrought H13 steel substrate, while that of the deposited D2 was lower than that of wrought D2. The evolution of the microstructures by deposition and heat treatment varied depending on the materials. In particular, the microstructure of the deposited D2 steel after heat treatment consisted of fine carbides in tempered martensite and it is expected that the deposited D2 steel will have isotropic properties and high hardness after heat treatment.

Electrochemical boriding and characterization of AISI D2 tool steel

International Nuclear Information System (INIS)

Sista, V.; Kahvecioglu, O.; Eryilmaz, O.L.; Erdemir, A.; Timur, S.

2011-01-01

D2 is an air-hardening tool steel and due to its high chromium content provides very good protection against wear and oxidation, especially at elevated temperatures. Boriding of D2 steel can further enhance its surface mechanical and tribological properties. Unfortunately, it has been very difficult to achieve a very dense and uniformly thick boride layers on D2 steel using traditional boriding processes. In an attempt to overcome such a deficiency, we explored the suitability and potential usefulness of electrochemical boriding for achieving thick and hard boride layers on this tool steel in a molten borax electrolyte at 850, 900, 950 and 1000 °C for durations ranging from 15 min to 1 h. The microstructural characterization and phase analysis of the resultant boride layers were performed using optical, scanning electron microscopy and X-ray diffraction methods. Our studies have confirmed that a single phase Fe 2 B layer or a composite layer consisting of FeB + Fe 2 B is feasible on the surface of D2 steel depending on the length of boriding time. The boride layers formed after shorter durations (i.e., 15 min) mainly consisted of Fe 2 B phase and was about 30 μm thick. The thickness of the layer formed in 60 min was about 60 μm and composed mainly of FeB and Fe 2 B. The cross sectional micro-hardness values of the boride layers varied between 14 and 22 GPa, depending on the phase composition.

Processing of an AISI D2 tool steel by high-energy milling

International Nuclear Information System (INIS)

Spagnol, N.J.R.; Araujo, G.F.; Vurobi Junior, S.; Cintho, O.M.

2009-01-01

Full text: Chips of machining of AISI D2 steel were processed in Spex high-energy mill. The powder obtained was analyzed by x-ray diffraction, and then compressed in the form of discs of 8mm in diameter. The samples were treated at 1200 deg C for 1 hour under vacuum atmosphere for sintering. Then specimens were subjected to annealing, quenching and tempering at 400°C and 525 deg C. Along with each disc, a sample of as-received steel was subjected to the same heat treatment to evaluate the final microstructures. After metallographic preparation, samples were etched with Berah's reagent, characterized by optical microscopy, Vickers hardness, quantitative metallography and scanning electron microscopy with micro analysis and mapping by EDS. Specimens from high energy milling had reduction in prior austenitic grain size and more refined carbides and better distributed in the microstructure of steel. (author)

Spinodal decomposition mechanism study on the duplex stainless steel UNS S31803 using ultrasonic speed measurements

International Nuclear Information System (INIS)

Albuquerque, Victor Hugo C. de; Macedo Silva, Edgard de; Pereira Leite, Josinaldo; Pindo de Moura, Elineudo; Araujo Freitas, Vera Lucia de; Tavares, Joao Manuel R.S.

2010-01-01

This work, focuses on the spinodal decomposition mechanism study on the duplex stainless steel duplex UNS S31803, composed by austenite (γ) and ferrite (α) phases, at 425 o C and 475 o C temperatures by ultrasonic speed measurements. This temperature range is responsible for the transformation mechanism of α initial phase to α phases (poor in chromium) and α' (rich in chromium) by spinodal decomposition. The techniques to accomplish this analysis are based mainly on X-ray diffraction measures and ultrasonic speed. The obtained results show that it is possible to conclude that the use of ultrasonic speed measurements indicates a promising technique for following-up the phase transformation and spinodal decomposition on the steel studied.

Determination of V, W and Mn in high-speed steel by neutron activation source of 241Am/Be

International Nuclear Information System (INIS)

Villar, H.P.; Galdino, S.M.L.; Godoy, M.O.; Dantas, C.C.

1982-01-01

Alloying elements are responsible for certain characteristics of the steels which enable their utilization for specific purposes. The concentrations of these elements must comply with strict standards, and the determination of these concentrations involve chemical analyses which are as a rule tedious and expensive. It is proposed here a fast and precise analytical process based on the neutron activation analysis. A significant correlation (r = 0.998) between manganese concentration and mean specific count rate of 56 Mn was obtained for activated tool steel samples. Later on, bases for tungsten vanadium determinations were set. (Author) [pt

Modelling and analysis of tool wear and surface roughness in hard turning of AISI D2 steel using response surface methodology

Directory of Open Access Journals (Sweden)

M. Junaid Mir

2018-01-01

Full Text Available The present work deals with some machinability studies on tool wear and surface roughness, in finish hard turning of AISI D2 steel using PCBN, Mixed ceramic and coated carbide inserts. The machining experiments are conducted based on the response surface methodology (RSM. Combined effects of three cutting parameters viz., cutting speed, cutting time and tool hardness on the two performance outputs (i.e. VB and Ra, are explored employing the analysis of variance (ANOVA.The relationship(s between input variables and the response parameters are determined using a quadratic regression model. The results show that the tool wear was influenced principally by the cutting time and in the second level by the cutting tool hardness. On the other hand, cutting time was the dominant factor affecting workpiece surface roughness followed by cutting speed. Finally, the multiple response optimizations of tool wear and surface roughness were carried out using the desirability function approach (DFA.

Investigation on grain refinement and precipitation strengthening applied in high speed wire rod containing vanadium

Energy Technology Data Exchange (ETDEWEB)

Wu, Da-yong; Xiao, Fu-ren, E-mail: frxiao@ysu.edu.cn; Wang, Bin; Liu, Jia-ling; Liao, Bo, E-mail: cyddjyjs@263.net

2014-01-13

To obtain necessary information for the simulation of high speed wire production process, the effect of grain refinement and precipitation strengthening on two high speed wire rod steels with different vanadium and nitrogen contents was investigated by continuous cooling transformation (CCT) characteristics. CCT curves were constructed by the dilatometer test and microscopic observation. Results showed that the formation of intra-granular ferrite (IGF) could refine grain remarkably and accelerate the ferrite transformation. Schedules for high speed wire production process focused on the effect of cooling rate. Ferrite grain was refined by increasing cooling rate and the formation of IGF. The microhardness calculation revealed that the steels were strengthened mostly by a combined effect of grain refinement and precipitation hardening. Degenerated pearlite was observed at lower transformation temperature and the fracture morphology changed from cementite lamellar to nanoscale cementite particle with increasing cooling rate. Based on the analysis above, an optimal schedule was applied and the microstructure and microhardness were improved.

Practical End-to-End Performance Testing Tool for High Speed 3G-Based Networks

Science.gov (United States)

Shinbo, Hiroyuki; Tagami, Atsushi; Ano, Shigehiro; Hasegawa, Toru; Suzuki, Kenji

High speed IP communication is a killer application for 3rd generation (3G) mobile systems. Thus 3G network operators should perform extensive tests to check whether expected end-to-end performances are provided to customers under various environments. An important objective of such tests is to check whether network nodes fulfill requirements to durations of processing packets because a long duration of such processing causes performance degradation. This requires testers (persons who do tests) to precisely know how long a packet is hold by various network nodes. Without any tool's help, this task is time-consuming and error prone. Thus we propose a multi-point packet header analysis tool which extracts and records packet headers with synchronized timestamps at multiple observation points. Such recorded packet headers enable testers to calculate such holding durations. The notable feature of this tool is that it is implemented on off-the shelf hardware platforms, i.e., lap-top personal computers. The key challenges of the implementation are precise clock synchronization without any special hardware and a sophisticated header extraction algorithm without any drop.

Factors influencing the surface quality of polished tool steels

International Nuclear Information System (INIS)

Rebeggiani, S; Rosén, B-G

2014-01-01

Today’s demands on surface quality of moulds for injection moulding of plastic components involve no/low defect contents and roughness levels in the nm-range for high gloss applications. Material properties as well as operating conditions influence the mould finish, and thus the final surface of moulded products. This paper focuses on how particle content and different polishing strategies influence final surface qualities of moulds. Visual estimations of polished tool steel samples were combined with non-contact 3D-surface texture analysis in order to correlate traditional assessments to more quantitative methods, and to be able to analyse the surfaces at nanometre-level. It was found that steels with a lower proportion of particles, like carbides and oxides, gave rise to smoother polished surfaces. In a comparative study of polishers from different polishing shops, it was found that while different surface preparation strategies can lead to similar final roughness, similar preparation techniques can produce high-quality surfaces from different steel grades. However, the non-contact 3D-surface texture analysis showed that not all smooth polished surfaces have desirable functional topographies for injection moulding of glossy plastic components. (paper)

Springback Prediction and Compensation for a High Strength Steel Side Impact Beam

International Nuclear Information System (INIS)

Dutton, Trevor; Edwards, Richard; Blowey, Andrew

2005-01-01

Prediction of formability for sheet metal pressings has advanced to a high state of confidence in recent years. The major challenge is now to predict springback and, moreover, to assist in the design of tooling to correctly compensate for springback. This is particularly the case for materials now being routinely considered for automotive production, such as aluminium and ultra high strength steels, which are prone to greater degrees of springback than traditional mild steels. This paper presents a case study based on the tool design for an ultra high strength steel side impact beam. The forming and springback simulations, carried out using eta/DYNAFORM (based on the LS-DYNA solver), are reported and compared to measurements from the prototype panels. The analysis parameters used in the simulation are presented, and the sensitivity of the results to variation in physical properties is also reviewed. The process of compensating the tools based on the analysis prediction is described; finally, an automated springback compensation method is also applied and the results compared with the final tool design

Nanocrystalline Ni-Co Alloy Synthesis by High Speed Electrodeposition

Directory of Open Access Journals (Sweden)

Jamaliah Idris

2013-01-01

Full Text Available Electrodeposition of nanocrystals is economically and technologically viable production path for the synthesis of pure metals and alloys both in coatings and bulk form. The study presents nanocrystalline Ni-Co alloy synthesis by high speed electrodeposition. Nanocrystalline Ni-Co alloys coatings were prepared by direct current (DC and deposited directly on steel and aluminum substrates without any pretreatment, using high speed electrodeposition method. The influence of the electrolysis parameters, such as cathodic current density and temperature at constant pH, on electrodeposition and microstructure of Ni-Co alloys were examined. A homogeneous surface morphology was obtained at all current densities of the plated samples, and it was evident that the current density and temperature affect the coating thickness of Ni-Co alloy coatings.

The functionally graded sintered steel WC-Co-NbC matrix

Energy Technology Data Exchange (ETDEWEB)

Santos, A.A.A.; Silva Junior, J.F. [Universidade Federal do Rio Grande do Norte (UFRN), Natal (Brazil)

2009-07-01

Full text: The high speed steels are used for machining, including cutting tools at high speeds because their wear resistance, high temperature properties and excellent hardness. They are ferrous based alloys of the Fe-C-X component system where X represents a group of elements comprising Cr, W or Mo, V and Co. The aim of this work was to study the feasibility of powder metallurgy technique to develop functionally graded alloy material added by WC, Co and NbC. The morphology of the composite powders and sintered MMC were characterized by scanning electron microscopy and XRD measurements. (author)

Carbides crystalline structure of AISI M2 high-speed steel

International Nuclear Information System (INIS)

Serna, M.M.; Galego, E.; Rossi, J.L.

2005-01-01

The aim of this study was to identify the crystallographic structure of the extracted carbides of AISI M2 steel spray formed The structure determination of these carbides. The structure determination of these carbides is a very hard work. Since these structures were formed by atom migration it is not possible to reproduce them by a controlled process with a determined chemical composition. The solution of this problem is to obtain the carbide by chemical extraction from the steel. (Author)

Study on the machinability characteristics of superalloy Inconel 718 during high speed turning

International Nuclear Information System (INIS)

Thakur, D.G.; Ramamoorthy, B.; Vijayaraghavan, L.

2009-01-01

The present paper is an attempt of an experimental investigation on the machinability of superalloy, Inconel 718 during high speed turning using tungsten carbide insert (K20) tool. The effect of machining parameters on the cutting force, specific cutting pressure, cutting temperature, tool wear and surface finish criteria were investigated during the experimentation. The machining parameters have been optimized by measuring forces. The effect of machining parameters on the tool wear was examined through SEM micrographs. During high speed turning acoustic emission signal were collected and analyzed to understand the effect of cutting parameters during online. The research work findings will also provide useful economic machining solution by utilizing economical tungsten carbide tooling during high speed processing of Inconel 718, which is otherwise usually machined by costly PCD or CBN tools. The present approach and results will be helpful for understanding the machinability of Inconel 718 during high speed turning for the manufacturing engineers

High speed turning of compacted graphite iron using controlled modulation

Science.gov (United States)

Stalbaum, Tyler Paul

Compacted graphite iron (CGI) is a material which emerged as a candidate material to replace cast iron (CI) in the automotive industry for engine block castings. Its thermal and mechanical properties allow the CGI-based engines to operate at higher cylinder pressures and temperatures than CI-based engines, allowing for lower fuel emissions and increased fuel economy. However, these same properties together with the thermomechanical wear mode in the CGI-CBN system result in poor machinability and inhibit CGI from seeing wide spread use in the automotive industry. In industry, machining of CGI is done only at low speeds, less than V = 200 m/min, to avoid encountering rapid wear of the cutting tools during cutting. Studies have suggested intermittent cutting operations such as milling suffer less severe tool wear than continuous cutting. Furthermore, evidence that a hard sulfide layer which forms over the cutting edge in machining CI at high speeds is absent during machining CGI is a major factor in the difference in machinability of these material systems. The present study addresses both of these issues by modification to the conventional machining process to allow intermittent continuous cutting. The application of controlled modulation superimposed onto the cutting process -- modulation-assisted machining (MAM) -- is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining CGI at high machining speeds (> 500 m/min). The tool life is at least 20 times greater than found in conventional machining of CGI. This significant reduction in wear is a consequence of reduction in the severity of the tool-work contact conditions with MAM. The propensity for thermochemical wear of CBN is thus reduced. It is found that higher cutting speed (> 700 m/min) leads to lower tool wear with MAM. The MAM configuration employing feed-direction modulation appears feasible for implementation at high speeds and offers a solution to this challenging

A High-Speed Train Operation Plan Inspection Simulation Model

Directory of Open Access Journals (Sweden)

Yang Rui

2018-01-01

Full Text Available We developed a train operation simulation tool to inspect a train operation plan. In applying an improved Petri Net, the train was regarded as a token, and the line and station were regarded as places, respectively, in accordance with the high-speed train operation characteristics and network function. Location change and running information transfer of the high-speed train were realized by customizing a variety of transitions. The model was built based on the concept of component combination, considering the random disturbance in the process of train running. The simulation framework can be generated quickly and the system operation can be completed according to the different test requirements and the required network data. We tested the simulation tool when used for the real-world Wuhan to Guangzhou high-speed line. The results showed that the proposed model can be developed, the simulation results basically coincide with the objective reality, and it can not only test the feasibility of the high-speed train operation plan, but also be used as a support model to develop the simulation platform with more capabilities.

Effect of the Ultrasonic Nanocrystalline Surface Modification (UNSM on Bulk and 3D-Printed AISI H13 Tool Steels

Directory of Open Access Journals (Sweden)

In-Sik Cho

2017-11-01

Full Text Available A comparative study of the microstructure, hardness, and tribological properties of two different AISI H13 tool steels—classified as the bulk with no heat treatment steel or the 3D-printed steel—was undertaken. Both samples were subjected to ultrasonic nanocrystalline surface modification (UNSM to further enhance their mechanical properties and improve their tribological behavior. The objective of this study was to compare the mechanical properties and tribological behavior of these tool steels since steel can exhibit a wide variety of mechanical properties depending on different manufacturing processes. The surface hardness of the samples was measured using a micro-Vickers hardness tester. The hardness of the 3D-printed AISI H13 tool steel was found to be much higher than that of the bulk one. The surface morphology of the samples was characterized by electron backscattered diffraction (EBSD in order to analyze the grain size and number of fractions with respect to the misorientation angle. The results revealed that the grain size of the 3D-printed AISI H13 tool steel was less than 0.5 μm, whereas that of the bulk tool steel was greater than 4 μm. The number of fractions of the bulk tool steel was about 0.5 μm at a low misorientation angle, and it decreased gradually with increasing misorientation angle. The low-angle grain boundary (LAGB and high-angle grain boundary (HAGB of the bulk sample were about 21% and 79%, respectively, and those of the 3D-printed sample were about 8% and 92%, respectively. Moreover, the friction and wear behavior of the UNSM-treated AISI H13 tool steel specimen was better than those of the untreated one. This study demonstrated the capability of 3D-printed AISI H13 tool steel to exhibit excellent mechanical and tribological properties for industrial applications.

SPEED DEPENDENCE OF ACOUSTIC VIBRATION PROPAGATION FROM THE FERRITIC GRAIN SIZE IN LOW-CARBON STEEL

Directory of Open Access Journals (Sweden)

I. A. Vakulenko

2015-08-01

Full Text Available Purpose. It is determining the nature of the ferrite grain size influence of low-carbon alloy steel on the speed propagation of acoustic vibrations. Methodology. The material for the research served a steel sheet of thickness 1.4 mm. Steel type H18T1 had a content of chemical elements within grade composition: 0, 12 % C, 17, 5 % Cr, 1 % Mn, 1, 1 % Ni, 0, 85 % Si, 0, 9 % Ti. The specified steel belongs to the semiferritic class of the accepted classification. The structural state of the metal for the study was obtained by cold plastic deformation by rolling at a reduction in the size range of 20-30 % and subsequent recrystallization annealing at 740 – 750 ° C. Different degrees of cold plastic deformation was obtained by pre-selection of the initial strip thickness so that after a desired amount of rolling reduction receives the same final thickness. The microstructure was observed under a light microscope, the ferrite grain size was determined using a quantitative metallographic technique. The using of X-ray structural analysis techniques allowed determining the level of second-order distortion of the crystal latitude of the ferrite. The speed propagation of acoustic vibrations was measured using a special device such as an ISP-12 with a working frequency of pulses 1.024 kHz. As the characteristic of strength used the hardness was evaluated by the Brinell’s method. Findings. With increasing of ferrite grain size the hardness of the steel is reduced. In the case of constant structural state of metal, reducing the size of the ferrite grains is accompanied by a natural increasing of the phase distortion. The dependence of the speed propagation of acoustic vibrations up and down the rolling direction of the ferrite grain size remained unchanged and reports directly proportional correlation. Originality. On the basis of studies to determine the direct impact of the proportional nature of the ferrite grain size on the rate of propagation of sound

Dimensional and material characteristics of direct deposited tool steel by CO II laser

Science.gov (United States)

Choi, J.

2006-01-01

Laser aided direct metalimaterial deposition (DMD) process builds metallic parts layer-by-layer directly from the CAD representation. In general, the process uses powdered metaUmaterials fed into a melt pool, creating fully dense parts. Success of this technology in the die and tool industry depends on the parts quality to be achieved. To obtain designed geometric dimensions and material properties, delicate control of the parameters such as laser power, spot diameter, traverse speed and powder mass flow rate is critical. In this paper, the dimensional and material characteristics of directed deposited H13 tool steel by CO II laser are investigated for the DMD process with a feedback height control system. The relationships between DMD process variables and the product characteristics are analyzed using statistical techniques. The performance of the DMD process is examined with the material characteristics of hardness, porosity, microstructure, and composition.

The use of high-speed imaging in education

Science.gov (United States)

Kleine, H.; McNamara, G.; Rayner, J.

2017-02-01

Recent improvements in camera technology and the associated improved access to high-speed camera equipment have made it possible to use high-speed imaging not only in a research environment but also specifically for educational purposes. This includes high-speed sequences that are created both with and for a target audience of students in high schools and universities. The primary goal is to engage students in scientific exploration by providing them with a tool that allows them to see and measure otherwise inaccessible phenomena. High-speed imaging has the potential to stimulate students' curiosity as the results are often surprising or may contradict initial assumptions. "Live" demonstrations in class or student- run experiments are highly suitable to have a profound influence on student learning. Another aspect is the production of high-speed images for demonstration purposes. While some of the approaches known from the application of high speed imaging in a research environment can simply be transferred, additional techniques must often be developed to make the results more easily accessible for the targeted audience. This paper describes a range of student-centered activities that can be undertaken which demonstrate how student engagement and learning can be enhanced through the use of high speed imaging using readily available technologies.

CHARACTERIZATION OF NEW TOOL STEEL FOR ALUMINUM EXTRUSION DIES

Directory of Open Access Journals (Sweden)

José Britti Bacalhau

2014-06-01

Full Text Available Aluminum extrusion dies are an important segment of application on industrial tools steels, which are manufactured in steels based on AISI H13 steel. The main properties of steels applied to extrusion dies are: wear resistance, impact resistance and tempering resistance. The present work discusses the characteristics of a newly developed hot work steel to be used on aluminum extrusion dies. The effects of Cr and Mo contents with respect to tempering resistance and the Al addition on the nitriding response have been evaluated. From forged steel bars, Charpy impact test and characterization via EPMA have been conducted. The proposed contents of Cr, Mo, and Al have attributed to the new VEX grade a much better tempering resistance than H13, as well as a deeper and harder nitrided layer. Due to the unique characteristics, this new steel provides an interesting alternative to the aluminum extrusion companies to increase their competitiveness.

Laser surface texturing of tool steel: textured surfaces quality evaluation

Science.gov (United States)

Šugár, Peter; Šugárová, Jana; Frnčík, Martin

2016-05-01

In this experimental investigation the laser surface texturing of tool steel of type 90MnCrV8 has been conducted. The 5-axis highly dynamic laser precision machining centre Lasertec 80 Shape equipped with the nano-second pulsed ytterbium fibre laser and CNC system Siemens 840 D was used. The planar and spherical surfaces first prepared by turning have been textured. The regular array of spherical and ellipsoidal dimples with a different dimensions and different surface density has been created. Laser surface texturing has been realized under different combinations of process parameters: pulse frequency, pulse energy and laser beam scanning speed. The morphological characterization of ablated surfaces has been performed using scanning electron microscopy (SEM) technique. The results show limited possibility of ns pulse fibre laser application to generate different surface structures for tribological modification of metallic materials. These structures were obtained by varying the processing conditions between surface ablation, to surface remelting. In all cases the areas of molten material and re-cast layers were observed on the bottom and walls of the dimples. Beside the influence of laser beam parameters on the machined surface quality during laser machining of regular hemispherical and elipsoidal dimple texture on parabolic and hemispherical surfaces has been studied.

Physically vapor deposited coatings on tools: performance and wear phenomena

International Nuclear Information System (INIS)

Koenig, W.; Fritsch, R.; Kammermeier, D.

1991-01-01

Coatings produced by physical vapor deposition (PVD) enhance the performance of tools for a broad variety of production processes. In addition to TiN, nowadays (Ti,Al)N and Ti(C,N) coated tools are available. This gives the opportunity to compare the performance of different coatings under identical machining conditions and to evaluate causes and phenomena of wear. TiN, (Ti,Al)N and Ti(C,N) coatings on high speed steel (HSS) show different performances in milling and turning of heat treated steel. The thermal and frictional properties of the coating materials affect the structure, the thickness and the flow of the chips, the contact area on the rake face and the tool life. Model tests show the influence of internal cooling and the thermal conductivity of coated HSS inserts. TiN and (Ti,Zr)N PVD coatings on cemented carbides were examined in interrupted turning and in milling of heat treated steel. Experimental results show a significant influence of typical time-temperature cycles of PVD and chemical vapor deposition (CVD) coating processes on the physical data and on the performance of the substrates. PVD coatings increase tool life, especially towards lower cutting speeds into ranges which cannot be applied with CVD coatings. The reason for this is the superior toughness of the PVD coated carbide. The combination of tough, micrograin carbide and PVD coating even enables broaching of case hardened sliding gears at a cutting speed of 66 m min -1 . (orig.)

Application of Fabry-Perot velocimeter to high-speed experiments

International Nuclear Information System (INIS)

Chaw, H.H.; McMillan, C.F.; Osher, J.E.

1988-01-01

The Fabry-Perot (F-P) velocimeter is a useful instrument for measuring the velocity of objects at speeds ranging from fractions of a kilometer per second to a few tens of kilometers per second and up. Because of its immunity to electromagnetic interference and its velocity resolution, it has become the prime diagnostic tool in our electric-gun facility. Examples of its application to high speed experiments are discussed, including: electric-gun flyer studies, spallation of materials under high-speed impact, momentum-transfer studies, pressure pulse created by high-velocity impact, and detonation-wave studies in high-explosive experiments

Microstructure and mechanical characterization of friction stir welded high strength low alloy steels

Energy Technology Data Exchange (ETDEWEB)

Ramesh, R., E-mail: rameshsmit@gmail.com [Department of Mechanical Engineering, PSG College of Technology, Coimbatore 641004, Tamilnadu (India); Dinaharan, I., E-mail: dinaweld2009@gmail.com [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006, Gauteng (South Africa); Kumar, Ravi, E-mail: nvrk@iitm.ac.in [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai 600036, Tamilnadu (India); Akinlabi, E.T., E-mail: etakinlabi@uj.ac.za [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006, Gauteng (South Africa)

2017-02-27

Friction stir welding (FSW) is a promising technique to join HSLA steels without the problems encountered during fusion based welding processes. In the present work, 3 mm thick HSLA plates were successfully welded using FSW. A tool made of tungsten-rhenium alloy was used in this work. The relationship between microstructure and tensile strength was studied under various welding conditions i.e. change in traverse speed (57–97 mm/min). The microstructure of the weld nugget revealed the presence of upper bainite and fine ferrite phases. The amount of upper bainite reduced with increase in traverse speed. EBSD images showed a reducing trend for grain size. The details of hardness, tensile strength and bending test were reported.

Microstructure and mechanical characterization of friction stir welded high strength low alloy steels

International Nuclear Information System (INIS)

Ramesh, R.; Dinaharan, I.; Kumar, Ravi; Akinlabi, E.T.

2017-01-01

Friction stir welding (FSW) is a promising technique to join HSLA steels without the problems encountered during fusion based welding processes. In the present work, 3 mm thick HSLA plates were successfully welded using FSW. A tool made of tungsten-rhenium alloy was used in this work. The relationship between microstructure and tensile strength was studied under various welding conditions i.e. change in traverse speed (57–97 mm/min). The microstructure of the weld nugget revealed the presence of upper bainite and fine ferrite phases. The amount of upper bainite reduced with increase in traverse speed. EBSD images showed a reducing trend for grain size. The details of hardness, tensile strength and bending test were reported.

Experimental research on the durability cutting tools for cutting-off steel profiles

Directory of Open Access Journals (Sweden)

Cristea Alexandru

2017-01-01

Full Text Available The production lines used for manufacturing U-shaped profiles are very complex and they must have high productivity. One of the most important stages of the fabrication process is the cutting-off. This paper presents the experimental research and analysis of the durability of the cutting tools used for cutting-off U-shaped metal steel profiles. The results of this work can be used to predict the durability of the cutting tools.

Influence of hot rolling and high speed hydrostatic extrusion on the microstructure and mechanical properties of an ODS RAF steel

Energy Technology Data Exchange (ETDEWEB)

Oksiuta, Z., E-mail: oksiuta@pb.edu.pl [Bialystok Technical University, Faculty of Mechanical Engineering, Wiejska 45c, 15-352 Bialystok (Poland); Lewandowska, M.; Kurzydlowski, K.J. [Warsaw University of Technology, Faculty of Materials Science and Engineering, Woloska 141, 02-504 Warsaw (Poland); Baluc, N. [Ecole Polytechnique Federale de Lausanne (EPFL), Centre de Recherches en Physique des Plasmas, Association Euratom-Confederation Suisse, 5232 Villigen PSI (Switzerland)

2011-02-15

An argon gas atomized, pre-alloyed Fe-14Cr-2W-0.3Ti (wt.%) reduced activation ferritic (RAF) steel powder was mechanically alloyed with 0.3wt.% Y{sub 2}O{sub 3} nano-particles in an attritor ball mill and consolidated by hot isostatic pressing at 1150 {sup o}C under a pressure of 200 MPa for 3 h. In the aim to improve its mechanical properties the ODS steel was then submitted to a thermo-mechanical treatment (TMT): hot rolling (HR) at 850 deg. C or high speed hydrostatic extrusion (HSHE) at 900 deg. C, followed by heat treatment (HT). Transmission electron microscopy (TEM) observations of the ODS alloys after TMT and heat treatment revealed the presence of elongated grains in the longitudinal direction, with an average width of 8 {mu}m and an average length of 75 {mu}m, and equiaxed grains, a few microns in diameter, in the transverse direction. Two populations of oxide particles were observed by TEM: large Ti-Al-O particles, up to 250 nm in diameter, usually located at the grain boundaries and small Y-Ti-O nanoclusters, about 2.5 nm in diameter, uniformly distributed in the matrix. Charpy impact tests revealed that the HSHE material exhibits a larger upper shelf energy (5.8 J) than the HR material (2.9 J). The ductile-to-brittle transition temperature of both alloys is relatively high, in the range of 55-72 deg. C. Tensile mechanical properties of both ODS alloys were found satisfactory over the full range of investigated temperatures (23-750 deg. C). The HSHE material exhibits better tensile strength and ductility than the HR material. These results indicate that HSHE can be considered as a promising TMT method for improving the mechanical properties of ODS RAF steels.

Measurement Research of Motorized Spindle Dynamic Stiffness under High Speed Rotating

Directory of Open Access Journals (Sweden)

Xiaopeng Wang

2015-01-01

Full Text Available High speed motorized spindle has become a key functional unit of high speed machine tools and effectively promotes the development of machine tool technology. The development of higher speed and more power puts forward the stricter requirement for the performance of motorized spindle, especially the dynamic performance which affects the machining accuracy, reliability, and production efficiency. To overcome the problems of ineffective loading and dynamic performance measurement of motorized spindle, a noncontact electromagnetic loading device is developed. The cutting load can be simulated by using electromagnetic force. A new method of measuring force by force sensors is presented, and the steady and transient loading force could be measured exactly. After the high speed machine spindle is tested, the frequency response curves of the spindle relative to machine table are collected at 0~12000 rpm; then the relationships between stiffness and speeds as well as between damping ratio and speeds are obtained. The result shows that not only the static and dynamic stiffness but also the damping ratio declined with the increase of speed.

Analysis of High Temperature Deformed Structure and Dynamic Precipitation in W9Mo3Cr4V Steel

Institute of Scientific and Technical Information of China (English)

无

2001-01-01

With TEM、SEM, various high-temperature deformed structures inW9Mo3Cr4V steel were investigated. The sub-structures，recrystallized nuclei, as well as the dynamic precipitation were also studied and analyzed. The relationship between recrystallized structures and dynamic precipitation was discussed. The results showed that the deformed structures in W9Mo3Cr4V steel are more complicated than those in low alloy steels. Because W9Mo3Cr4V steel is a high-speed steel, there are a large number of residual carbides on the matrix. Also, much dynamic precipitating carbides will precipitate during deformation at high temperature.

Changing in tool steels wear resistance under electron irradiation

International Nuclear Information System (INIS)

Braginskaya, A.E.; Manin, V.N.; Makedonskij, A.V.; Mel'nikova, N.A.; Pakchanin, L.M.; Petrenko, P.V.

1983-01-01

The tool steels and alloys wear resistance under dry friction after electron irradiation has been studied. Electron irradiation of a wide variety of steels is shown to increase wear resistance. In this case phase composition and lattice parameters changes are observed both in matrix and carbides. The conclusion is drawn that an appreciable increase of steel wear resistance under electron irradiation can be explained both by carbide phase volume gain and changes in it's composition and the formation of carbide phase submicroscopic heterogeneities and, possibly, complexes of defects

Boride Formation Induced by pcBN Tool Wear in Friction-Stir-Welded Stainless Steels

Science.gov (United States)

Park, Seung Hwan C.; Sato, Yutaka S.; Kokawa, Hiroyuki; Okamoto, Kazutaka; Hirano, Satoshi; Inagaki, Masahisa

2009-03-01

The wear of polycrystalline cubic boron nitride (pcBN) tool and its effect on second phase formation were investigated in stainless steel friction-stir (FS) welds. The nitrogen content and the flow stress were analyzed in these welds to examine pcBN tool wear. The nitrogen content in stir zone (SZ) was found to be higher in the austenitic stainless steel FS welds than in the ferritic and duplex stainless steel welds. The flow stress of austenitic stainless steels was almost 1.5 times larger than that of ferritic and duplex stainless steels. These results suggest that the higher flow stress causes the severe tool wear in austenitic stainless steels, which results in greater nitrogen pickup in austenitic stainless steel FS welds. From the microstructural observation, a possibility was suggested that Cr-rich borides with a crystallographic structure of Cr2B and Cr5B3 formed through the reaction between the increased boron and nitrogen and the matrix during FS welding (FSW).

Effect of work material composition on the wear life of TiN-coated tools

Energy Technology Data Exchange (ETDEWEB)

Harju, E. [Helsinki Univ. of Technol., Espoo (Finland). Dept. of Materials Science and Engineering; Korhonen, A.S. [Helsinki Univ. of Technol., Espoo (Finland). Dept. of Materials Science and Engineering; Jiang Laizhu [Dept. of Mechanical Engineering, Helsinki Univ. of Technology, Espoo (Finland); Ristolainen, E. [Centre for Chemical Analysis, Helsinki Univ. of Technology, Espoo (Finland)

1996-11-15

Three commercially available quenched and tempered steels corresponding approximately to AISI 4140 were compared in dry turning using both uncoated and TiN-coated high-speed steel (HSS) inserts. Of three steels A, B and C, steel A did not contain added calcium, while both B and C were calcium-treated. In dry turning with uncoated HSS inserts steel B was best. It gave over 2 times longer wear life than steel A and 1 1/2 times longer than steel C. When the inserts were coated with TiN, the cutting speed could be increased and the order of performance changed dramatically. Steel C was then best, giving nearly 26 times longer wear life than steel A and 9 times longer wear life than steel B. Based on secondary ion mass spectroscopy measurements, the enrichment of alloying elements was studied on the tool surface. The formation of an adherent protective layer on the rake face during turning of steel C is proposed as a mechanism explaining the observed differences in wear lives. (orig.)

Effect of work material composition on the wear life of TiN-coated tools

International Nuclear Information System (INIS)

Harju, E.; Ristolainen, E.

1996-01-01

Three commercially available quenched and tempered steels corresponding approximately to AISI 4140 were compared in dry turning using both uncoated and TiN-coated high-speed steel (HSS) inserts. Of three steels A, B and C, steel A did not contain added calcium, while both B and C were calcium-treated. In dry turning with uncoated HSS inserts steel B was best. It gave over 2 times longer wear life than steel A and 1 1/2 times longer than steel C. When the inserts were coated with TiN, the cutting speed could be increased and the order of performance changed dramatically. Steel C was then best, giving nearly 26 times longer wear life than steel A and 9 times longer wear life than steel B. Based on secondary ion mass spectroscopy measurements, the enrichment of alloying elements was studied on the tool surface. The formation of an adherent protective layer on the rake face during turning of steel C is proposed as a mechanism explaining the observed differences in wear lives. (orig.)

Effect of Energy Input on the Characteristic of AISI H13 and D2 Tool Steels Deposited by a Directed Energy Deposition Process

Science.gov (United States)

Park, Jun Seok; Park, Joo Hyun; Lee, Min-Gyu; Sung, Ji Hyun; Cha, Kyoung Je; Kim, Da Hye

2016-05-01

Among the many additive manufacturing technologies, the directed energy deposition (DED) process has attracted significant attention because of the application of metal products. Metal deposited by the DED process has different properties than wrought metal because of the rapid solidification rate, the high thermal gradient between the deposited metal and substrate, etc. Additionally, many operating parameters, such as laser power, beam diameter, traverse speed, and powder mass flow rate, must be considered since the characteristics of the deposited metal are affected by the operating parameters. In the present study, the effect of energy input on the characteristics of H13 and D2 steels deposited by a direct metal tooling process based on the DED process was investigated. In particular, we report that the hardness of the deposited H13 and D2 steels decreased with increasing energy input, which we discuss by considering microstructural observations and thermodynamics.

The optimization study on the tool wear of carbide cutting tool during milling Carbon Fibre Reinforced (CFRP) using Response Surface Methodology (RSM)

Science.gov (United States)

Nor Khairusshima, M. K.; Hafiz Zakwan, B. Muhammad; Suhaily, M.; Sharifah, I. S. S.; Shaffiar, N. M.; Rashid, M. A. N.

2018-01-01

Carbon Fibre Reinforced Plastic (CFRP) composite has become one of famous materials in industry, such as automotive, aeronautics, aerospace and aircraft. CFRP is attractive due to its properties, which promising better strength and high specification of mechanical properties other than its high resistance to corrosion. Other than being abrasive material due to the carbon nature, CFRP is an anisotropic material, which the knowledge of machining metal and steel cannot be applied during machining CFRP. The improper technique and parameters used to machine CFRP may result in high tool wear. This paper is to study the tool wear of 8 mm diameter carbide cutting tool during milling CFRP. To predict the suitable cutting parameters within range of 3500-6220 (rev/min), 200-245 (mm/min), and 0.4-1.8 (mm) for cutting speed, speed, feed rate and depth of cut respectively, which produce optimized result (less tool wear), Response Surface Methodology (RSM) has been used. Based on the developed mathematical model, feed rate was identified as the primary significant item that influenced tool wear. The optimized cutting parameters are cutting speed, feed and depth of cut of 3500 rev/min, 200 mm/min and 0.5 mm, respectively, with tool wear of 0.0267 mm. It is also can be observed that as the cutting speed and feed rate increased the tool wear is increasing.

Investigation of fatigue strength of tool steels in sheet-bulk metal forming

Science.gov (United States)

Pilz, F.; Gröbel, D.; Merklein, M.

2018-05-01

To encounter trends regarding an efficient production of complex functional components in forming technology, the process class of sheet-bulk metal forming (SBMF) can be applied. SBMF is characterized by the application of bulk forming operations on sheet metal, often in combination with sheet forming operations [1]. The combination of these conventional process classes leads to locally varying load conditions. The resulting load conditions cause high tool loads, which lead to a reduced tool life, and an uncontrolled material flow. Several studies have shown that locally modified tool surfaces, so-called tailored surfaces, have the potential to control the material flow and thus to increase the die filling of functional elements [2]. A combination of these modified tool surfaces and high tool loads in SBMF is furthermore critical for the tool life and leads to fatigue. Tool fatigue is hardly predictable and due to a lack of data [3], a challenge in tool design. Thus, it is necessary to provide such data for tool steels used in SBMF. The aim of this study is the investigation of the influence of tailored surfaces on the fatigue strength of the powder metallurgical tool steel ASP2023 (1.3344, AISI M3:2), which is typically used in cold forging applications, with a hardness 60 HRC ± 1 HRC. To conduct this investigation, the rotating bending test is chosen. As tailored surfaces, a DLC-coating and a surface manufactured by a high-feed-milling process are chosen. As reference a polished surface which is typical for cold forging tools is used. Before the rotating bending test, the surface integrity is characterized by measuring topography and residual stresses. After testing, the determined values of the surface integrity are correlated with the reached fracture load cycle to derive functional relations. Based on the gained results the investigated tailored surfaces are evaluated regarding their feasibility to modify tool surfaces within SBMF.

Thermomechanical modelling of laser surface glazing for H13 tool steel

Science.gov (United States)

Kabir, I. R.; Yin, D.; Tamanna, N.; Naher, S.

2018-03-01

A two-dimensional thermomechanical finite element (FE) model of laser surface glazing (LSG) has been developed for H13 tool steel. The direct coupling technique of ANSYS 17.2 (APDL) has been utilised to solve the transient thermomechanical process. A H13 tool steel cylindrical cross-section has been modelled for laser power 200 W and 300 W at constant 0.2 mm beam width and 0.15 ms residence time. The model can predict temperature distribution, stress-strain increments in elastic and plastic region with time and space. The crack formation tendency also can be assumed by analysing the von Mises stress in the heat-concentrated zone. Isotropic and kinematic hardening models have been applied separately to predict the after-yield phenomena. At 200 W laser power, the peak surface temperature achieved is 1520 K which is below the melting point (1727 K) of H13 tool steel. For laser power 300 W, the peak surface temperature is 2523 K. Tensile residual stresses on surface have been found after cooling, which are in agreement with literature. Isotropic model shows higher residual stress that increases with laser power. Conversely, kinematic model gives lower residual stress which decreases with laser power. Therefore, both plasticity models could work in LSG for H13 tool steel.

Comparative study of the interface composition of TiN and TiCN hard coatings on high speed steel substrates obtained by arc discharge

Energy Technology Data Exchange (ETDEWEB)

Roman, E. (Lab. de Fisica de Superficies, Inst. de Ciencia de Materiales, CSIC, Madrid (Spain)); Segovia, J.L. de (Lab. de Fisica de Superficies, Inst. de Ciencia de Materiales, CSIC, Madrid (Spain)); Alberdi, A. (TEKNIKER, Asociacion de Investigacion Tecnologica, Eibar (Spain)); Calvo, J. (TEKNIKER, Asociacion de Investigacion Tecnologica, Eibar (Spain)); Laucirica, J. (TEKNIKER, Asociacion de Investigacion Tecnologica, Eibar (Spain))

1993-05-15

In this paper the composition of the interface of TiN and TiCN hard coatings deposited onto high speed steel substrates obtained by the arc discharge technique is studied using Auger electron spectroscopy at two different substrate temperatures, 520 K and 720 K. The low temperature (520 K) TiN coating developed an oxygen phase at the interface, producing a weak adherence of 40 N, while the high temperature coatings (720 K) had a less intense oxygen phase, giving a greater adherence to the substrate of 60 N. TiCN coatings at 520 K are characterized by a low oxygen intensity at the interface. However, their adherence of 50 N is lower than the value of 60 N for the high temperature TiN coatings and is independent of the substrate temperature. (orig.)

Influence of minimum quantity of lubricant (MQL on tool life of carbide cutting tools during milling process of steel AISI 1018

Directory of Open Access Journals (Sweden)

Diego Núñez

2017-03-01

Full Text Available Nowadays, high productivity of machining is an important issue to obtain economic benefits in the industry. This purpose could be reached with high cutting velocity and feed rate. However, the inherently behavior produce high temperatures in the interface of couple cutting tool/workpiece. Many cutting fluids have been developed to control temperature in process and increase tool life. The objective of this paper is to compare the carbide milling tool wear using different systems cutting fluids: flood and minimum quantity of lubrication (MQL. The values of carbide milling cutting tool wear was evaluate according with the standard ISO 8688-1 1989. The experimental results showed that using MQL reduces significantly (about 40% tool wear in milling AISI 1018 steel at industrial cutting conditions.

Study of the performances of nano-case treatment cutting tools on carbon steel work material during turning operation

Science.gov (United States)

Afolalu, S. A.; Okokpujie, I. P.; Salawu, E. Y.; Abioye, A. A.; Abioye, O. P.; Ikumapayi, O. M.

2018-04-01

The degree of holding temperature and time play a major role in nano-case treatment of cutting tools which immensely contributed to its performance during machining operation. The objective of this research work is to carryout comparative study of performance of nano-case treatment tools developed using low and medium carbon steel as work piece. Turning operation was carried out under two different categories with specific work piece on universal lathe machine using HSS cutting tools 100 mm × 12mm × 12mm that has been nano-case treated under varying conditions of temperatures and timeof 800,850, 900, 950°C and 60, 90, 120 mins respectively. The turning parameters used in evaluating this experiment were cutting speed of 270, 380 and 560mm/min, feed rate of 0.15, 0.20 and 0.25 mm/min, depth of cut of 2mm, work piece diameter of 25mm and rake angle of 7° each at three levels. The results of comparative study of their performances revealed that the timespent in the machining of low carbon steel material at a minimum temperature and time of 800°C, 60 mins were1.50, 2.17 mins while at maximum temperature and time of 950°C, 120 mins were 1.19, 2.02 mins. It was also observed that at a corresponding constant speed of 270,380 and 560mm/min at higher temperature and time, a relative increased in the length of cut were observed. Critical observation of the result showed that at higher case hardening temperature and time (950°C/120mins), the HSS cutting tool gave a better performance as lesser time was consumed during the turning operation.

Compressibility, turbulence and high speed flow

CERN Document Server

Gatski, Thomas B

2013-01-01

Compressibility, Turbulence and High Speed Flow introduces the reader to the field of compressible turbulence and compressible turbulent flows across a broad speed range, through a unique complimentary treatment of both the theoretical foundations and the measurement and analysis tools currently used. The book provides the reader with the necessary background and current trends in the theoretical and experimental aspects of compressible turbulent flows and compressible turbulence. Detailed derivations of the pertinent equations describing the motion of such turbulent flows is provided and an extensive discussion of the various approaches used in predicting both free shear and wall bounded flows is presented. Experimental measurement techniques common to the compressible flow regime are introduced with particular emphasis on the unique challenges presented by high speed flows. Both experimental and numerical simulation work is supplied throughout to provide the reader with an overall perspective of current tre...

Cadence® High-Speed PCB Layout Flow Workshop

CERN Document Server

2003-01-01

Last release of Cadence High-Speed PCB Design methodology (PE142) based on Concept-HDL schematic editor, Constraint Manager, SPECCTRAQuest signal integrity analysis tool and ALLEGRO layout associated with SPECCTRA auto router tools, is now enough developed and stable to be taken into account for high-speed board designs at CERN. The implementation of this methodology, build around the new Constraint Manager program, is essential when you have to develop a board having a lot of high-speed design rules such as terminated lines, large bus structures, maximum length, timing, crosstalk etc.. that could not be under control by traditional method. On more conventional designs, formal aspect of the methodology could avoid misunderstanding between hardware and ALLEGRO layout designers, minimizing prototype iteration, development time and price. The capability to keep trace of the original digital designer intents in schematic or board layout, loading formal constraints in EDMS, could also be considered for LHC electro...

Fatigue resistance of welded joints in aluminium high-speed craft : A total stress concept

NARCIS (Netherlands)

Den Besten, J.H.

2015-01-01

Crew transfers, surveillance duties and {security, rescue, interception} operations at sea typically require high-speed craft. Aluminium is quite often selected as hull structure material because of its weight save potential in comparison to steel. The fatigue strength, however, may become a point

High Performance Grinding and Advanced Cutting Tools

CERN Document Server

Jackson, Mark J

2013-01-01

High Performance Grinding and Advanced Cutting Tools discusses the fundamentals and advances in high performance grinding processes, and provides a complete overview of newly-developing areas in the field. Topics covered are grinding tool formulation and structure, grinding wheel design and conditioning and applications using high performance grinding wheels. Also included are heat treatment strategies for grinding tools, using grinding tools for high speed applications, laser-based and diamond dressing techniques, high-efficiency deep grinding, VIPER grinding, and new grinding wheels.

Assessment of the effect of Nd:YAG laser pulse operating parameters on the metallurgical characteristics of different tool steels using DOE software

Directory of Open Access Journals (Sweden)

T. Muhič

2011-04-01

Full Text Available To ensure the reliability of repair welded tool surfaces, clad quality should be improved. The relationships between metallurgical characteristics of cladding and laser input welding parameters were studied using the design of experiments software. The influence of laser power, welding speed, focal point position and diameter of welding wire on the weld-bead geometry (i.e. penetration, cladding zone width and heat-affected-zone width, microstructural homogeneity, dilution and bond strength was investigated on commonly used tool steels 1,2083, 1,2312 and 1,2343, using DOE software.

Automatic X-ray television rig for high-speed radiography of polycrystals

International Nuclear Information System (INIS)

Bezbakh, V.D.; Garasim, Yu.A.; Oshkaderov, S.P.; Pet'kov, V.V.

1993-01-01

The high-speed radiography method is used for studying the phase and structural transformation in metals and alloys during rapid changes in temperature. In order to improve the effectiveness of this method the Institute of Metal Physics, Ukrainian Academy of Sciences, has developed an automatic rig for high-speed radiography of polycrystalline materials using a television method for recording the x-ray diffraction patterns. The rig, described here, consists of an x-ray block, a vacuum chamber, a device for programmed electro-contact heating of specimens, a system for imaging and scanning x-ray diffraction patterns, and a system for collecting and analyzing the data. Focusing is carried out by the Zeeman-Bolin method. The new rig helps to significantly reduce the recording time and ensures adequate quality and reliability of the recorded diffraction image over a wide range of temperatures. Data using the rig is presented for high-speed radiography for cooling a specimen of G20 steel. 4 refs., 4 figs

Refining the microstructure of an AISI M2 tool steel by high-energy milling

International Nuclear Information System (INIS)

Postiglioni, R.V.; Alamino, A.E; Vurobi Junior, S.

2009-01-01

Samples of AISI M2 steel were produced by high-energy milling from chips of machining in Spex high energy mill, compaction and sintering of the powder obtained. The powder was analyzed by X-ray diffraction, and then compressed in discs of 8mm in diameter. The specimens have sintering at 1200 deg C for 1 hour under vacuum atmosphere, followed by annealing, quenching and tempering for 1 hour at 315 deg C and 540°C. Along with each disc, a sample of as-received steel was subjected to the same heat treatments to compare the final microstructure. After standard metallographic preparation, samples were etched with Beraha's reagent, characterized by optical microscopy, quantitative metallography, scanning electron microscopy with micro analysis and mapping by EDS, besides Vickers hardness. The steel produced by high-energy milling presented more refined carbide and better distribution in the microstructure. There was also reduction in the size of prior austenitic grains. (author)

Enhanced wear resistance of production tools and steel samples by implantation of nitrogen and carbon ions

International Nuclear Information System (INIS)

Mikkelsen, N.J.; Straede, C.A.

1992-01-01

In recent years ion implantation has become a feasible technique for obtaining improved wear resistance of production tools. However, basic knowledge of how and in which cases ion implantation is working at its best is still needed. The present paper discusses structural and tribological investigations of carbon and nitrogen implanted steels. The nitrogen data were obtained mainly from field tests and the investigation of carbon implantations took place mainly in the laboratory. A study was made of how the tribological behaviour of implanted steels changes with different implantation parameters. The tribological laboratory investigations were carried out using pin-on-disc equipment under controlled test conditions, and deal with high dose carbon implantation (approximately (1-2)x10 18 ions cm -2 ). The wear resistance of steels was enhanced dramatically, by up to several orders of magnitude. The field test results cover a broad range of ion implanted production tools, which showed a marked improvement in wear resistance. Nitrogen implanted tools are also compared with carbon and titanium implanted tools. (orig.)

Modeling the Spray Forming of H13 Steel Tooling

Science.gov (United States)

Lin, Yaojun; McHugh, Kevin M.; Zhou, Yizhang; Lavernia, Enrique J.

2007-07-01

On the basis of a numerical model, the temperature and liquid fraction of spray-formed H13 tool steel are calculated as a function of time. Results show that a preheated substrate at the appropriate temperature can lead to very low porosity by increasing the liquid fraction in the deposited steel. The calculated cooling rate can lead to a microstructure consisting of martensite, lower bainite, retained austenite, and proeutectoid carbides in as-spray-formed material. In the temperature range between the solidus and liquidus temperatures, the calculated temperature of the spray-formed material increases with increasing substrate preheat temperature, resulting in a very low porosity by increasing the liquid fraction of the deposited steel. In the temperature region where austenite decomposition occurs, the substrate preheat temperature has a negligible influence on the cooling rate of the spray-formed material. On the basis of the calculated results, it is possible to generate sufficient liquid fraction during spray forming by using a high growth rate of the deposit without preheating the substrate, and the growth rate of the deposit has almost no influence on the cooling rate in the temperature region of austenite decomposition.

Surface Roughness Optimization Using Taguchi Method of High Speed End Milling For Hardened Steel D2

Science.gov (United States)

Hazza Faizi Al-Hazza, Muataz; Ibrahim, Nur Asmawiyah bt; Adesta, Erry T. Y.; Khan, Ahsan Ali; Abdullah Sidek, Atiah Bt.

2017-03-01

The main challenge for any manufacturer is to achieve higher quality of their final products with maintains minimum machining time. In this research final surface roughness analysed and optimized with maximum 0.3 mm flank wear length. The experiment was investigated the effect of cutting speed, feed rate and depth of cut on the final surface roughness using D2 as a work piece hardened to 52-56 HRC, and coated carbide as cutting tool with higher cutting speed 120-240 mm/min. The experiment has been conducted using L9 design of Taguchi collection. The results have been analysed using JMP software.

Cutting Temperature Investigation of AISI H13 in High Speed End Milling

Directory of Open Access Journals (Sweden)

Muhammad Riza

2016-10-01

Full Text Available Heat produced at the tool-chip interface during high speed milling operations have been known as a significant factor that affect to tool life and workpiece geometry or properties. This paper aims to investigate cutting temperature behaviours of AISI H13 (48 HRC under high speed machining circumstances during pocketing. The experiments were conducted on CNC vertical machining centre by using PVD coated carbide insert. Milling processes were done at cutting speeds 150, 200 and 250 m/min and feed rate were 0.05, 0.1 and 0.15 mm/tooth. Depths of cut applied were 0.1, 0.15 and 0.2 mm. Tool path method applied in this experiment was contour in. Results presented in this paper indicate that by increasing cutting speed the cutting temperature is lower than low cutting speed. However, by decreasing feed rate leads to cutting temperature low. Cutting temperature phenomena at the corner of pocket milling were also investigated. The phenomena showed that cutting temperature tends to decrease a moment when cutter comes to the corner of pocket and turning point of tool path and increase extremely a moment before leaving the corner and turning point.

Micro-Bulges Investigation on Laser Modified Tool Steel Surface

Directory of Open Access Journals (Sweden)

Fauzun Fazliana

2017-01-01

Full Text Available This paper presents micro-bulges investigation on laser modified tool steel. The aim of this study is to understand the effect of laser irradiance and interaction time on surface morphology configuration. An Nd:YAG laser system with TEM00 pulse processing mode was used to modify the samples. Metallographic study shows samples were analyzed for focal position effect on melted pool size, angle of peaks geometry and laser modified layer depth. Surface morphology were analyzed for surface roughness. Laser modified layer shows depth ranged between 42.22 and 420.12 μm. Angle of peak bulge was found to be increase with increasing peak power. The maximum roughness, Ra, achieved in modified H13 was 21.10 μm. These findings are significant to enhance surface properties of laser modified steel and cast iron for dies and high wear resistance applications.

Crystalline gamma-Al2O3 physical vapour deposition-coating for steel thixoforging tools.

Science.gov (United States)

Bobzin, K; Hirt, G; Bagcivan, N; Khizhnyakova, L; Ewering, M

2011-10-01

The process of thixoforming, which has been part of many researches during the last decades, combines the advantages of forging and casting for the shaping of metallic components. But due to the high temperatures of semi-solid steel alloys high demands on the tools are requested. To resists the thermal and mechanical loads (wear, friction, thermal and thermomechanical fatigue) protecting thin films are necessary. In this regard crystalline gamma-Al2O3 deposited via Physical Vapour Deposition (PVD) is a promising candidate: It exhibits high thermal stability, high oxidation resistance and high hot hardness. In the present work the application of a (Ti, Al)N/gamma-Al2O3 coating deposited by means of Magnetron Sputter Ion Plating in an industrial coating unit is presented. The coating was analysed by means of Rockwell test, nanoindentation, and Scanning Electron Microscopy (SEM). The coated tool was tested in thixoforging experiments with steel grade X210CrW12 (AlSI D6). The surface of the coated dies was examined with Scanning Electron Microscope (SEM) after 22, 42, 90 and 170 forging cycles.

Experimental study of residual stresses in laser clad AISI P20 tool steel on pre-hardened wrought P20 substrate

International Nuclear Information System (INIS)

Chen, J.-Y.; Conlon, K.; Xue, L.; Rogge, R.

2010-01-01

Research highlights: → Laser cladding of P20 tool steel. → Residual stress analysis of laser clad P20 tool steel. → Microstructure of laser clad P20 tool steel. → Tooling Repair using laser cladding. → Stress reliving treatment of laser clad P20 tool steel. - Abstract: Laser cladding is to deposit desired material onto the surface of a base material (or substrate) with a relatively low heat input to form a metallurgically sound and dense clad. This process has been successfully applied for repairing damaged high-value tooling to reduce their through-life cost. However, laser cladding, which needs to melt a small amount of a substrate along with cladding material, inevitably introduces residual stresses in both clad and substrate. The tensile residual stresses in the clad could adversely affect mechanical performance of the substrate being deposited. This paper presents an experimental study on process-induced residual stresses in laser clad AISI P20 tool steel onto pre-hardened wrought P20 base material and the correlation with microstructures using hole-drilling and neutron diffraction methods. Combined with X-ray diffraction and scanning electron microscopic analyses, the roles of solid-state phase transformations in the clad and heat-affected zone (HAZ) of the substrate during cladding and post-cladding heat treatments on the development and controllability of residual stresses in the P20 clad have been investigated, and the results could be beneficial to more effective repair of damaged plastic injection molds made by P20 tool steel.

Prediction of ttt curves of cold working tool steels using support vector machine model

Science.gov (United States)

Pillai, Nandakumar; Karthikeyan, R., Dr.

2018-04-01

The cold working tool steels are of high carbon steels with metallic alloy additions which impart higher hardenability, abrasion resistance and less distortion in quenching. The microstructure changes occurring in tool steel during heat treatment is of very much importance as the final properties of the steel depends upon these changes occurred during the process. In order to obtain the desired performance the alloy constituents and its ratio plays a vital role as the steel transformation itself is complex in nature and depends very much upon the time and temperature. The proper treatment can deliver satisfactory results, at the same time process deviation can completely spoil the results. So knowing time temperature transformation (TTT) of phases is very critical which varies for each type depending upon its constituents and proportion range. To obtain adequate post heat treatment properties the percentage of retained austenite should be lower and metallic carbides obtained should be fine in nature. Support vector machine is a computational model which can learn from the observed data and use these to predict or solve using mathematical model. Back propagation feedback network will be created and trained for further solutions. The points on the TTT curve for the known transformations curves are used to plot the curves for different materials. These data will be trained to predict TTT curves for other steels having similar alloying constituents but with different proportion range. The proposed methodology can be used for prediction of TTT curves for cold working steels and can be used for prediction of phases for different heat treatment methods.

Nitriding of high speed steel

International Nuclear Information System (INIS)

Doyle, E.D.; Pagon, A.M.; Hubbard, P.; Dowey, S.J.; Pilkington, A.; McCulloch, D.G.; Latham, K.; DuPlessis, J.

2010-01-01

Current practice when nitriding HSS cutting tools is to avoid embrittlement of the cutting edge by limiting the depth of the diffusion zone. This is accomplished by reducing the nitriding time and temperature and eliminating any compound layer formation. However, in many applications there is an argument for generating a compound layer with beneficial tribological properties. In this investigation results are presented of a metallographic, XRD and XPS analysis of nitrided surface layers generated using active screen plasma nitriding and reactive vapour deposition using cathodic arc. These results are discussed in the context of built up edge formation observed while machining inside a scanning electron microscope. (author)

Problems in repair-welding of duplex-treated tool steels

OpenAIRE

T. Muhič; J. Tušek; M. Pleterski; D. Bombač

2009-01-01

The present paper addresses problems in laser welding of die-cast tools used for aluminum pressure die-castings and plastic moulds. To extend life cycle of tools various surface improvements are used. These surface improvements significantly reduce weldability of the material. This paper presents development of defects in repair welding of duplex-treated tool steel. The procedure is aimed at reduction of defects by the newly developed repair laser welding techniques. Effects of different repa...

Computational Model for Impact-Resisting Critical Thickness of High-Speed Machine Outer Protective Plate

Science.gov (United States)

Wu, Huaying; Wang, Li Zhong; Wang, Yantao; Yuan, Xiaolei

2018-05-01

The blade or surface grinding blade of the hypervelocity grinding wheel may be damaged due to too high rotation rate of the spindle of the machine and then fly out. Its speed as a projectile may severely endanger the field persons. Critical thickness model of the protective plate of the high-speed machine is studied in this paper. For easy analysis, the shapes of the possible impact objects flying from the high-speed machine are simplified as sharp-nose model, ball-nose model and flat-nose model. Whose front ending shape to represent point, line and surface contacting. Impact analysis based on J-C model is performed for the low-carbon steel plate with different thicknesses in this paper. One critical thickness computational model for the protective plate of high-speed machine is established according to the damage characteristics of the thin plate to get relation among plate thickness and mass, shape and size and impact speed of impact object. The air cannon is used for impact test. The model accuracy is validated. This model can guide identification of the thickness of single-layer outer protective plate of a high-speed machine.

EXPERIMENTAL INVESTIGATION OF THE TOOL-CHIP INTERFACE TMPERATURES ON UNCOATED CEMENTIDE CARBIDE CUTTING TOOLS

Directory of Open Access Journals (Sweden)

Kasım HABALI

2005-01-01

Full Text Available It is known that the temperature as the result of the heat developed during machining at the tool-chip interface has an influence on the tool life and workpiece surface guality and the methods for measuring this temperature are constantly under investigation. In this study, the measurement of tool-chip interface temperature using toolworkpiece termocouple method was investigated. The test were carried out on a AISI 1040 steel and the toolchip interface temperature variation was examined depending on the cutting speed and feed rate. The obtained groups show that cutting speed has more influence on the temperature than feedrate has.

Erosion Behaviour of API X100 Pipeline Steel at Various Impact Angles and Particle Speeds

Directory of Open Access Journals (Sweden)

Paul C. Okonkwo

2016-09-01

Full Text Available Erosion is the gradual removal of material due to solid particle impingement and results in a failure of pipeline materials. In this study, a series of erosion tests were carried out to investigate the influence of particle speed and impact angle on the erosion mechanism of API X100 pipeline steel. A dry erosion machine was used as the test equipment, while the particle speed ranged from 20 to 80 m/s and impact angles of 30° and 90° were used as test parameters. The eroded API X100 steel surface was characterized using scanning electron microscope (SEM and X-ray photoelectron spectroscopy (XPS. The weight loss and erosion rate were also investigated. The results showed that at a 90° impact angle, a ploughing mechanism was occurring on the tested specimens, while material removal through low-angle cutting was the dominant mechanism at lower impact angles. Embedment of alumina particles on the target steel surface, micro-cutting, and low-angle cutting were observed at low impact angles. Therefore, the scratches, cuttings, and severe ploughings observed on some failed oil and gas pipelines could be attributed to the erosion mechanism.

Nugget Structure Evolution with Rotation Speed for High-Rotation-Speed Friction-Stir-Welded 6061 Aluminum Alloy

Science.gov (United States)

Zhang, H. J.; Wang, M.; Zhu, Z.; Zhang, X.; Yu, T.; Wu, Z. Q.

2018-03-01

High-rotation-speed friction stir welding (HRS-FSW) is a promising technique to reduce the welding loads during FSW and thus facilitates the application of FSW for in situ fabrication and repair. In this study, 6061 aluminum alloy was friction stir welded at high-rotation speeds ranging from 3000 to 7000 rpm at a fixed welding speed of 50 mm/min, and the effects of rotation speed on the nugget zone macro- and microstructures were investigated in detail in order to illuminate the process features. Temperature measurements during HRS-FSW indicated that the peak temperature did not increase consistently with rotation speed; instead, it dropped remarkably at 5000 rpm because of the lowering of material shear stress. The nugget size first increased with rotation speed until 5000 rpm and then decreased due to the change of the dominant tool/workpiece contact condition from sticking to sliding. At the rotation speed of 5000 rpm, where the weld material experienced weaker thermal effect and higher-strain-rate plastic deformation, the nugget exhibited relatively small grain size, large textural intensity, and high dislocation density. Consequently, the joint showed superior nugget hardness and simultaneously a slightly low tensile ductility.

Optimization of cutting parameters in CNC turning of stainless steel 304 with TiAlN nano coated carbide cutting tool

Science.gov (United States)

Durga Prasada Rao, V.; Harsha, N.; Raghu Ram, N. S.; Navya Geethika, V.

2018-02-01

In this work, turning was performed to optimize the surface finish or roughness (Ra) of stainless steel 304 with uncoated and coated carbide tools under dry conditions. The carbide tools were coated with Titanium Aluminium Nitride (TiAlN) nano coating using Physical Vapour Deposition (PVD) method. The machining parameters, viz., cutting speed, depth of cut and feed rate which show major impact on Ra are considered during turning. The experiments are designed as per Taguchi orthogonal array and machining process is done accordingly. Then second-order regression equations have been developed on the basis of experimental results for Ra in terms of machining parameters used. Regarding the effect of machining parameters, an upward trend is observed in Ra with respect to feed rate, and as cutting speed increases the Ra value increased slightly due to chatter and vibrations. The adequacy of response variable (Ra) is tested by conducting additional experiments. The predicted Ra values are found to be a close match of their corresponding experimental values of uncoated and coated tools. The corresponding average % errors are found to be within the acceptable limits. Then the surface roughness equations of uncoated and coated tools are set as the objectives of optimization problem and are solved by using Differential Evolution (DE) algorithm. Also the tool lives of uncoated and coated tools are predicted by using Taylor’s tool life equation.

An experimental study of flank wear in the end milling of AISI 316 stainless steel with coated carbide inserts

Science.gov (United States)

Odedeyi, P. B.; Abou-El-Hossein, K.; Liman, M.

2017-05-01

Stainless steel 316 is a difficult-to-machine iron-based alloys that contain minimum of about 12% of chromium commonly used in marine and aerospace industry. This paper presents an experimental study of the tool wear propagation variations in the end milling of stainless steel 316 with coated carbide inserts. The milling tests were conducted at three different cutting speeds while feed rate and depth of cut were at (0.02, 0.06 and 01) mm/rev and (1, 2 and 3) mm, respectively. The cutting tool used was TiAlN-PVD-multi-layered coated carbides. The effects of cutting speed, cutting tool coating top layer and workpiece material were investigated on the tool life. The results showed that cutting speed significantly affected the machined flank wears values. With increasing cutting speed, the flank wear values decreased. The experimental results showed that significant flank wear was the major and predominant failure mode affecting the tool life.

High-speed infrared imaging for material characterization in experimental mechanics experiments

Science.gov (United States)

Gagnon, Marc-André; Marcotte, Frédérick; Lagueux, Philippe; Farley, Vincent; Guyot, Éric; Morton, Vince

2017-10-01

Heat transfers are involved in many phenomena such as friction, tensile stress, shear stress and material rupture. Among the challenges encountered during the characterization of such thermal patterns is the need for both high spatial and temporal resolution. Infrared imaging provides information about surface temperature that can be attributed to the stress response of the material and breaking of chemical bounds. In order to illustrate this concept, tensile and shear tests were carried out on steel, aluminum and carbon fiber composite materials and monitored using high-speed (Telops FASTM2K) and high-definition (Telops HD-IR) infrared imaging. Results from split-Hopkinson experiments carried out on a polymer material at high strain-rate are also presented. The results illustrate how high-speed and high-definition infrared imaging in the midwave infrared (MWIR, 3 - 5 μm) spectral range can provide detailed information about the thermal properties of materials undergoing mechanical testing.

High-performance circular sawing of AISI 1045 steel with cermet and tungsten carbide inserts

International Nuclear Information System (INIS)

Abrao, A. M.; Rubio, J. C. Campos; Moreira, C.; Faria, P. E.

2014-01-01

This work investigated the influence of cutting speed and feed rate on cutting forces, surface roughness, and slot width circular sawing of AISI 1045 steel. The effects of tool material (cermet and tungsten carbide) and geometry (chip breaker flute and pre-cutting/postcutting teeth) were also investigated. Thrust and radial forces generally tended to decrease as the cutting speed increased and tended to increase with the feed rate. The lowest values of thrust and radial forces were obtained using a tungsten carbide saw ground with precutting and post-cutting teeth. With regard to the quality of the machined wall, the lowest surface roughness was obtained by applying the highest cutting speed and lowest feed rate and employing a cermet brazed saw. Under this condition, roughness values comparable to face turning and parting off operations were obtained. The cermet brazed saw was responsible for producing the narrowest slot widths.

Effect of microstructure on the impact toughness of high strength steels

Energy Technology Data Exchange (ETDEWEB)

Gutierrez, I.

2014-07-01

One of the major challenges in the development of new steel grades is to get increasingly high strength combined with a low ductile brittle transition temperature and a high upper shelf energy. This requires the appropriate microstructural design. Toughness in steels is controlled by different microstructural constituents. Some of them, like inclusions, are intrinsic while others happening at different microstructural scales relate to processing conditions. A series of empirical equations express the transition temperature as a sum of contributions from substitutional solutes, free nitrogen, carbides, pearlite, grain size and eventually precipitation strengthening. Aimed at developing a methodology that could be applied to high strength steels, microstructures with a selected degree of complexity were produced at laboratory in a Nb-microalloyed steel. As a result a model has been developed that consistently predicts the Charpy curves for ferrite-pearlite, bainitic and quenched and tempered microstructures using as input data microstructural parameters. This model becomes a good tool for microstructural design. (Author)

Experimental and Numerical Investigations of Applying Tip-bottomed Tool for Bending Advanced Ultra-high Strength Steel Sheet

Science.gov (United States)

Mitsomwang, Pusit; Borrisutthekul, Rattana; Klaiw-awoot, Ken; Pattalung, Aran

2017-09-01

This research was carried out aiming to investigate the application of a tip-bottomed tool for bending an advanced ultra-high strength steel sheet. The V-die bending experiment of a dual phase steel (DP980) sheet which had a thickness of 1.6 mm was executed using a conventional bending and a tip-bottomed punches. Experimental results revealed that the springback of the bent worksheet in the case of the tip-bottomed punch was less than that of the conventional punch case. To further discuss bending characteristics, a finite element (FE) model was developed and used to simulate the bending of the worksheet. From the FE analysis, it was found that the application of the tip-bottomed punch contributed the plastic deformation to occur at the bending region. Consequently, the springback of the worksheet reduced. In addition, the width of the punch tip was found to affect the deformation at the bending region and determined the springback of the bent worksheet. Moreover, the use of the tip-bottomed punch resulted in the apparent increase of the surface hardness of the bent worksheet, compared to the bending with the conventional punch.

Effect of Deep Cryogenic treatment on AISI A8 Tool steel & Development of Wear Mechanism maps using Fuzzy Clustering

Science.gov (United States)

Pillai, Nandakumar; Karthikeyan, R., Dr.

2018-04-01

Tool steels are widely classified according to their constituents and type of thermal treatments carried out to obtain its properties. Viking a special purpose tool steel coming under AISI A8 cold working steel classification is widely used for heavy duty blanking and forming operations. The optimum combination of wear resistance and toughness as well as ease of machinability in pre-treated condition makes this material accepted in heavy cutting and non cutting tool manufacture. Air or vacuum hardening is recommended as the normal treatment procedure to obtain the desired mechanical and tribological properties for steels under this category. In this study, we are incorporating a deep cryogenic phase within the conventional treatment cycle both before and after tempering. The thermal treatments at sub zero temperatures up to -195°C using cryogenic chamber with liquid nitrogen as medium was conducted. Micro structural changes in its microstructure and the corresponding improvement in the tribological and physical properties are analyzed. The cryogenic treatment leads to more conversion of retained austenite to martensite and also formation of fine secondary carbides. The microstructure is studied using the micrographs taken using optical microscopy. The wear tests are conducted on DUCOM tribometer for different combinations of speed and load under normal temperature. The wear rates and coefficient of friction obtained from these experiments are used to developed wear mechanism maps with the help of fuzzy c means clustering and probabilistic neural network models. Fuzzy C means clustering is an effective algorithm to group data of similar patterns. The wear mechanisms obtained from the computationally developed maps are then compared with the SEM photographs taken and the improvement in properties due to this additional cryogenic treatment is validated.

Discriminations of critical conditions of a high speed ship in quarterings sea waves by using tools of the sea state determinations by GMS. Eisei joho kaisho settei shien tool ni motozuku chokosokusen no shatsuiha rinkai jotai no hanmei

Energy Technology Data Exchange (ETDEWEB)

Yamaguchi, S.; +Ishida, T. (Kyushu University, Fukuoka (Japan)); Shinkai, A. (Kyushu University, Fukuoka (Japan). Faculty of Engineering)

1991-09-04

The documentation assumes a new type high speed ship, higher than 50kt in speed and heavier than 1000ton in dead weight, to require the ocean goingness, middle distance navigation and high speed transport. The present report dealed with how to discriminate a ship, navigating at a high speed on oceanic waves, in critical condition against the encountering waves. Navigating far distantly from the shore, the ship was generally made to positively utilize the information data from the geostationary metheorological satellite (GMS) to be applied as a support soft tool for the maritime system and other designs. As a result, the high speed ship on the quartering waves was numerically elucidated in critical condition against the encountering waves and simultaneously assumed in critical course upon discriminating the critical condition in a concretely designated oceanic area. It was shown that, if different Froude numbers are calculated and ordered of critical circular frequency, angle, wave period, etc. against the encountering, a dimensionally arbitrary ship is easily discriminatable in critical course in an arbitrary oceanic area by utilizing a GMS determination support tool. 12 refs., 14 figs., 2 tabs.

Wear-Induced Changes in FSW Tool Pin Profile: Effect of Process Parameters

Science.gov (United States)

Sahlot, Pankaj; Jha, Kaushal; Dey, G. K.; Arora, Amit

2018-06-01

Friction stir welding (FSW) of high melting point metallic (HMPM) materials has limited application due to tool wear and relatively short tool life. Tool wear changes the profile of the tool pin and adversely affects weld properties. A quantitative understanding of tool wear and tool pin profile is crucial to develop the process for joining of HMPM materials. Here we present a quantitative wear study of H13 steel tool pin profile for FSW of CuCrZr alloy. The tool pin profile is analyzed at multiple traverse distances for welding with various tool rotational and traverse speeds. The results indicate that measured wear depth is small near the pin root and significantly increases towards the tip. Near the pin tip, wear depth increases with increase in tool rotational speed. However, change in wear depth near the pin root is minimal. Wear depth also increases with decrease in tool traverse speeds. Tool pin wear from the bottom results in pin length reduction, which is greater for higher tool rotational speeds, and longer traverse distances. The pin profile changes due to wear and result in root defect for long traverse distance. This quantitative understanding of tool wear would be helpful to estimate tool wear, optimize process parameters, and tool pin shape during FSW of HMPM materials.

Tribological properties of ceramics evaluated at low sliding speeds

International Nuclear Information System (INIS)

Hayashi, Kazunori; Kano, Shigeki

1998-03-01

Low speed tribological properties of stainless steel, ceramics and hard metals were investigated in air at room temperature and in nitrogen atmosphere at high temperature for the consideration of sliding type support structure in intermediate heat exchanger of fast reactor. The following results are obtained. (1) In low speed friction measurements in air at room temperature, friction coefficients of ceramics and hard metals were smaller than that of stainless steel. Surface roughness of the specimens increased the friction force and silicon carbide showed the smallest friction coefficient among the specimens with mirror polished surface. (2) From the results of friction measurements at various sliding speeds in air at room temperature, friction coefficients of ceramics and hard metals were always stable and lower than that of stainless steel. Among ceramics, PSZ showed the smallest friction and silicon carbide showed the most stable friction at any sliding speeds. (3) Friction coefficients of silicon carbide and silicon nitride in nitrogen atmosphere at high temperature showed low values as measured at room temperature. On the contrary, friction coefficient of stainless steel measured in nitrogen atmosphere at high temperature were higher than that measured at room temperature, over 1. (4) In the reciprocal sliding tests in nitrogen atmosphere at high temperature, friction coefficient of stainless steel were over 1. On the contrary, the friction coefficients of ceramics were less than 1 instead of chipping during the slidings. (author)

High speed atom source

International Nuclear Information System (INIS)

Hoshino, Hitoshi.

1990-01-01

In a high speed atom source, since the speed is not identical between ions and electrons, no sufficient neutralizing effect for ionic rays due to the mixing of the ionic rays and the electron rays can be obtained failing to obtain high speed atomic rays at high density. In view of the above, a speed control means is disposed for equalizing the speed of ions forming ionic rays and the speed of electrons forming electron rays. Further, incident angle of the electron rays and/or ionic rays to a magnet or an electrode is made variable. As a result, the relative speed between the ions and the electrons to the processing direction is reduced to zero, in which the probability of association between the ions and the electrons due to the coulomb force is increased to improve the neutralizing efficiency to easily obtain fine and high density high speed electron rays. Further, by varying the incident angle, a track capable of obtaining an ideal mixing depending on the energy of the neutralized ionic rays is formed. Since the high speed electron rays has such high density, they can be irradiated easily to the minute region of the specimen. (N.H.)

Modeling and simulation of high-speed milling centers dynamics

OpenAIRE

Msaddek , El Bechir; Bouaziz , Zoubeir; Baili , Maher; Dessein , Gilles

2011-01-01

International audience; High-speed machining is a milling operation in industrial production of aeronautic parts, molds, and dies. The parts production is being reduced because of the slowing down of the machining resulting from the tool path discontinuity machining strategy. In this article, we propose a simulation tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting tool feed rate. Afterwards, a simulati...

Tool steel ion beam assisted nitrocarburization

International Nuclear Information System (INIS)

Zagonel, L.F.; Alvarez, F.

2007-01-01

The nitrocarburization of the AISI-H13 tool steel by ion beam assisted deposition is reported. In this technique, a carbon film is continuously deposited over the sample by the ion beam sputtering of a carbon target while a second ion source is used to bombard the sample with low energy nitrogen ions. The results show that the presence of carbon has an important impact on the crystalline and microstructural properties of the material without modification of the case depth

Visualization of high speed liquid jet impaction on a moving surface.

Science.gov (United States)

Guo, Yuchen; Green, Sheldon

2015-04-17

Two apparatuses for examining liquid jet impingement on a high-speed moving surface are described: an air cannon device (for examining surface speeds between 0 and 25 m/sec) and a spinning disk device (for examining surface speeds between 15 and 100 m/sec). The air cannon linear traverse is a pneumatic energy-powered system that is designed to accelerate a metal rail surface mounted on top of a wooden projectile. A pressurized cylinder fitted with a solenoid valve rapidly releases pressurized air into the barrel, forcing the projectile down the cannon barrel. The projectile travels beneath a spray nozzle, which impinges a liquid jet onto its metal upper surface, and the projectile then hits a stopping mechanism. A camera records the jet impingement, and a pressure transducer records the spray nozzle backpressure. The spinning disk set-up consists of a steel disk that reaches speeds of 500 to 3,000 rpm via a variable frequency drive (VFD) motor. A spray system similar to that of the air cannon generates a liquid jet that impinges onto the spinning disc, and cameras placed at several optical access points record the jet impingement. Video recordings of jet impingement processes are recorded and examined to determine whether the outcome of impingement is splash, splatter, or deposition. The apparatuses are the first that involve the high speed impingement of low-Reynolds-number liquid jets on high speed moving surfaces. In addition to its rail industry applications, the described technique may be used for technical and industrial purposes such as steelmaking and may be relevant to high-speed 3D printing.

Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel

International Nuclear Information System (INIS)

Jafarzadegan, M.; Feng, A.H.; Abdollah-zadeh, A.; Saeid, T.; Shen, J.; Assadi, H.

2012-01-01

In the present study, 3 mm-thick plates of 304 stainless steel and st37 steel were welded together by friction stir welding at a welding speed of 50 mm/min and tool rotational speed of 400 and 800 rpm. X-ray diffraction test was carried out to study the phases which might be formed in the welds. Metallographic examinations, and tensile and microhardness tests were used to analyze the microstructure and mechanical properties of the joint. Four different zones were found in the weld area except the base metals. In the stir zone of the 304 stainless steel, a refined grain structure with some features of dynamic recrystallization was evidenced. A thermomechanically-affected zone was characterized on the 304 steel side with features of dynamic recovery. In the other side of the stir zone, the hot deformation of the st37 steel in the austenite region produced small austenite grains and these grains transformed to fine ferrite and pearlite and some products of displacive transformations such as Widmanstatten ferrite and martensite by cooling the material after friction stir welding. The heat-affected zone in the st37 steel side showed partially and fully refined microstructures like fusion welding processes. The recrystallization in the 304 steel and the transformations in the st37 steel enhanced the hardness of the weld area and therefore, improved the tensile properties of the joint. - Highlights: ► FSW produced sound welds between st37 low carbon steel and 304 stainless steel. ► The SZ of the st37 steel contained some products of allotropic transformation. ► The material in the SZ of the 304 steel showed features of dynamic recrystallization. ► The finer microstructure in the SZ increased the hardness and tensile strength.

Comparative study of coated and uncoated tool inserts with dry machining of EN47 steel using Taguchi L9 optimization technique

Science.gov (United States)

Vasu, M.; Shivananda, Nayaka H.

2018-04-01

EN47 steel samples are machined on a self-centered lathe using Chemical Vapor Deposition of coated TiCN/Al2O3/TiN and uncoated tungsten carbide tool inserts, with nose radius 0.8mm. Results are compared with each other and optimized using statistical tool. Input (cutting) parameters that are considered in this work are feed rate (f), cutting speed (Vc), and depth of cut (ap), the optimization criteria are based on the Taguchi (L9) orthogonal array. ANOVA method is adopted to evaluate the statistical significance and also percentage contribution for each model. Multiple response characteristics namely cutting force (Fz), tool tip temperature (T) and surface roughness (Ra) are evaluated. The results discovered that coated tool insert (TiCN/Al2O3/TiN) exhibits 1.27 and 1.29 times better than the uncoated tool insert for tool tip temperature and surface roughness respectively. A slight increase in cutting force was observed for coated tools.

Friction stir processing on high carbon steel U12

Energy Technology Data Exchange (ETDEWEB)

Tarasov, S. Yu., E-mail: tsy@ispms.ru; Rubtsov, V. E., E-mail: rvy@ispms.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation); Melnikov, A. G., E-mail: melnikov-ag@tpu.ru [National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation)

2015-10-27

Friction stir processing (FSP) of high carbon steel (U12) samples has been carried out using a milling machine and tools made of cemented tungsten carbide. The FSP tool has been made in the shape of 5×5×1.5 mm. The microstructural characterization of obtained stir zone and heat affected zone has been carried out. Microhardness at the level of 700 MPa has been obtained in the stir zone with microstructure consisting of large grains and cementitte network. This high-level of microhardness is explained by bainitic reaction developing from decarburization of austenitic grains during cementite network formation.

Experimental Evaluation of a High Speed Flywheel for an Energy Cache System

Science.gov (United States)

Haruna, J.; Murai, K.; Itoh, J.; Yamada, N.; Hirano, Y.; Fujimori, T.; Homma, T.

2011-03-01

A flywheel energy cache system (FECS) is a mechanical battery that can charge/discharge electricity by converting it into the kinetic energy of a rotating flywheel, and vice versa. Compared to a chemical battery, a FECS has great advantages in durability and lifetime, especially in hot or cold environments. Design simulations of the FECS were carried out to clarify the effects of the composition and dimensions of the flywheel rotor on the charge/discharge performance. The rotation speed of a flywheel is limited by the strength of the materials from which it is constructed. Three materials, carbon fiber-reinforced polymer (CFRP), Cr-Mo steel, and a Mg alloy were examined with respect to the required weight and rotation speed for a 3 MJ (0.8 kWh) charging/discharging energy, which is suitable for an FECS operating with a 3-5 kW photovoltaic device in an ordinary home connected to a smart grid. The results demonstrate that, for a stationary 3 MJ FECS, Cr-Mo steel was the most cost-effective, but also the heaviest, Mg-alloy had a good balance of rotation speed and weight, which should result in reduced mechanical loss and enhanced durability and lifetime of the system, and CFRP should be used for applications requiring compactness and a higher energy density. Finally, a high-speed prototype FW was analyzed to evaluate its fundamental characteristics both under acceleration and in the steady state.

Experimental Evaluation of a High Speed Flywheel for an Energy Cache System

International Nuclear Information System (INIS)

Haruna, J; Itoh, J; Murai, K; Yamada, N; Hirano, Y; Homma, T; Fujimori, T

2011-01-01

A flywheel energy cache system (FECS) is a mechanical battery that can charge/discharge electricity by converting it into the kinetic energy of a rotating flywheel, and vice versa. Compared to a chemical battery, a FECS has great advantages in durability and lifetime, especially in hot or cold environments. Design simulations of the FECS were carried out to clarify the effects of the composition and dimensions of the flywheel rotor on the charge/discharge performance. The rotation speed of a flywheel is limited by the strength of the materials from which it is constructed. Three materials, carbon fiber-reinforced polymer (CFRP), Cr-Mo steel, and a Mg alloy were examined with respect to the required weight and rotation speed for a 3 MJ (0.8 kWh) charging/discharging energy, which is suitable for an FECS operating with a 3-5 kW photovoltaic device in an ordinary home connected to a smart grid. The results demonstrate that, for a stationary 3 MJ FECS, Cr-Mo steel was the most cost-effective, but also the heaviest, Mg-alloy had a good balance of rotation speed and weight, which should result in reduced mechanical loss and enhanced durability and lifetime of the system, and CFRP should be used for applications requiring compactness and a higher energy density. Finally, a high-speed prototype FW was analyzed to evaluate its fundamental characteristics both under acceleration and in the steady state.

Effect of cerium and lanthanum on the microstructure and mechanical properties of AISI D2 tool steel

International Nuclear Information System (INIS)

Hamidzadeh, Mohammad Ali; Meratian, Mahmood; Saatchi, Ahmad

2013-01-01

AISI D2 tool steel has excellent wear resistance with high dimensional stability. This type of steel is suitable for making molds. This paper describes investigations into the effect of adding Ce/La on microstructure of AISI D2 type cold work tool steels obtained by means of optical microscopy, scanning electron microscopy, X-ray diffraction, energy dispersive X-ray spectrometry (EDS) and image analyzer. The results showed that after modification with Ce/La, the morphology, size and distribution of M 7 C 3 carbides change greatly. The carbide network tends to break, and all carbides are refined and distributed homogeneously in the matrix, and also reduce the size of chromium carbides and increase the dissolution of carbides during heat treatment. The results of mechanical tests show that the toughness of the alloy increased about 75% without reducing the hardness of the alloy

Evaluation of Dynamic Load Factors for a High-Speed Railway Truss Arch Bridge

Directory of Open Access Journals (Sweden)

Ding Youliang

2016-01-01

Full Text Available Studies on dynamic impact of high-speed trains on long-span bridges are important for the design and evaluation of high-speed railway bridges. The use of the dynamic load factor (DLF to account for the impact effect has been widely accepted in bridge engineering. Although the field monitoring studies are the most dependable way to study the actual DLF of the bridge, according to previous studies there are few field monitoring data on high-speed railway truss arch bridges. This paper presents an evaluation of DLF based on field monitoring and finite element simulation of Nanjing DaShengGuan Bridge, which is a high-speed railway truss arch bridge with the longest span throughout the world. The DLFs in different members of steel truss arch are measured using monitoring data and simulated using finite element model, respectively. The effects of lane position, number of train carriages, and speed of trains on DLF are further investigated. By using the accumulative probability function of the Generalized Extreme Value Distribution, the probability distribution model of DLF is proposed, based on which the standard value of DLF within 50-year return period is evaluated and compared with different bridge design codes.

Weldability of Advanced High Strength Steels using Ytterbium:Yttrium Aluminium Garnet high power laser for Tailor-Welded Blank applications

Science.gov (United States)

Sharma, Rajashekhar Shivaram

Use of a high power Yb:YAG laser is investigated for joining advanced high strength steel materials for use in tailor-welded blank (TWB) applications. TWB's are materials of different chemistry, coating or thicknesses that are joined before metal forming and other operations such as trimming, assembly and painting are carried out. TWB is becoming an important design tool in the automotive industry for reducing weight, improving fuel economy and passenger safety, while reducing the overall costs for the customer. Three advanced high strength steels, TRIP780, DP980 and USIBOR, which have many unique properties that are conducive to achieving these objectives, along with mild steel, are used in this work. The objective of this work is to ensure that high quality welds can be obtained using Yb:YAG lasers which are also becoming popular for metal joining operations, since they produce high quality laser beams that suffer minimal distortion when transported via fiber optic cables. Various power levels and speeds for the laser beam were used during the investigation. Argon gas was consistently used for shielding purposes during the welding process. After the samples were welded, metallographic examination of the fusion and heat-affected zones using optical and scanning electron microscopes were carried out to determine the microstructures as well as weld defects. Optical and scanning electron microscopes were also used to examine the top of welds as well as fracture surfaces. Additionally, cross-weld microhardness evaluations, tensile tests using Instron tester, limited fatigue tests as well as formability evaluations using OSU plane strain evaluation were carried out. The examinations included a 2-factor full factorial design of experiments to determine the impact of coatings on the surface roughness on the top of the welds. Tensile strengths of DP980, TRIP780 and mild steel materials as well as DP980 welded to TRIP780 and mild steel in the rolling direction as well as

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process

OpenAIRE

Dhandapani, N. V.; Thangarasu, V. S.; Sureshkannan, G.

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the...

A LOW TEMPERATURE ALUMINIZING TREATMENT OF HOT WORK TOOL STEEL

OpenAIRE

Matijević, Božidar

2013-01-01

Conventional aluminizing processes by pack cementation are typically carried out at elevated temperatures. A low temperature powder aluminizing technology was applied to the X40CrMoV5-1 hot tool steel. The aluminizing temperature was from 550 °C to 620 °C. Effects of temperature and time on the microstructure and phase evolution were investigated. Also, the intermetallic layer thickness was measured in the aluminized layer of a steel substrate. The cross-sectional microstructures, the alumini...

Microstructure and mechanical properties of friction stir welded 18Cr–2Mo ferritic stainless steel thick plate

International Nuclear Information System (INIS)

Han, Jian; Li, Huijun; Zhu, Zhixiong; Barbaro, Frank; Jiang, Laizhu; Xu, Haigang; Ma, Li

2014-01-01

Highlights: • We focus on friction stir welding of 18Cr–2Mo ferritic stainless steel thick plate. • We produce high-quality joints with special tool and optimised welding parameters. • We compare microstructure and mechanical properties of steel and joint. • Friction stir welding is a method that can maintain the properties of joint. - Abstract: In this study, microstructure and mechanical properties of a friction stir welded 18Cr–2Mo ferritic stainless steel thick plate were investigated. The 5.4 mm thick plates with excellent properties were welded at a constant rotational speed and a changeable welding speed using a composite tool featuring a chosen volume fraction of cubic boron nitride (cBN) in a W–Re matrix. The high-quality welds were successfully produced with optimised welding parameters, and studied by means of optical microscopy (OM), scanning electron microscopy (SEM), electron back-scattered diffraction (EBSD) and standard hardness and impact toughness testing. The results show that microstructure and mechanical properties of the joints are affected greatly, which is mainly related to the remarkably fine-grained microstructure of equiaxed ferrite that is observed in the friction stir welded joint. Meanwhile, the ratios of low-angle grain boundary in the stir zone regions significantly increase, and the texture turns strong. Compared with the base material, mechanical properties of the joint are maintained in a comparatively high level

Compresibility and sinterability of HCx PM steel diluted with stainless steels

Directory of Open Access Journals (Sweden)

Elena Gordo

2003-12-01

Full Text Available HCx powder metallurgy steel contains in its composition high contents of Cr and C, and significant quantities of alloy elements typical of tool steels (Mo, V, W, to provide the corrosion resistance of stainless steel with wear resistance of tool steels. HCx appears to be a suitable material for applications in aggressive environments, as valve seat inserts in automotive engines. However, this steel presents a low compressibility leading to high production costs. In this work, some results carried out to improve the compressibility of HCx are presented. The way to attempt this improvement is the dilution of base material with two stainless steels, the ferritic 430LHC and the austenitic 316L. The powder mixes prepared were uniaxially pressed to study the compressibility. The sinterability was study by determining of density, hardness, transverse rupture strength (TRS and microstructural evolution after vacuum sintering at different temperatures. As a result, better compressibility is observed in the mixes although not all of them present the properties required.

EXPERIMENTAL RESEARCH REGARDING THE INFLUENCE OF CUTTING REGIME ON THE WEAR OF DRILLS AT STEEL PROCESSING

Directory of Open Access Journals (Sweden)

Leonard Marius CIUREZU GHERGHE

2015-05-01

Full Text Available This paper aims to highlight the influence of cutting regime on the wear drills at steel processing , in particular the processing of stainless steel X17CrNi16-2 SR EN 10088-4 DIN 17440. We are interested in wear of the drill at processing of this type of stainless steel , which has applicability in energy industry given the special characteristics of its. We want a maximum value of 0.2 mm for the wear of the drill, measurement and taking pictures are made using a microscope DigiMicro 2.0 and the software used is MicroCapture. Processing was done on machining center YMC YOUNG TECH 1050, and the tool used was 8 mm drill bit high speed steel.

Problems in repair-welding of duplex-treated tool steels

Directory of Open Access Journals (Sweden)

T. Muhič

2009-01-01

Full Text Available The present paper addresses problems in laser welding of die-cast tools used for aluminum pressure die-castings and plastic moulds. To extend life cycle of tools various surface improvements are used. These surface improvements significantly reduce weldability of the material. This paper presents development of defects in repair welding of duplex-treated tool steel. The procedure is aimed at reduction of defects by the newly developed repair laser welding techniques. Effects of different repair welding process parameters and techniques are considered. A microstructural analysis is conducted to detect defect formation and reveal the best laser welding method for duplex-treated tools.

Chemical analysis of steel by optical emission spectrometry

International Nuclear Information System (INIS)

Hayakawa, M.O.; Kajita, T.; Jeszensky, G.

1981-01-01

The development of the chemical analysis for special steels by optical emission spectrometry direct reading method with computer, at the Siderurgica N.S. Aparecida S.A. is presented. Results are presented for the low alloy steels and high speed steel. Also, the contribution of this method to the special steel preparation is commented. (Author) [pt

Interfacial fatigue stress in PVD TiN coated tool steels under rolling contact fatigue conditions

NARCIS (Netherlands)

Carvalho, N.J.M.; Huis in 't Veld, A.J.; Hosson, J.T. de

1998-01-01

Titanium-nitrogen (TiN) films were Physical Vapour Deposited (PVD) on tool steel substrates with different hardness and surface roughness, in a Bai 640R unit using a triode ion plating (e-gun) with a high plasma density. The coated substrates were submitted to a rolling contact fatigue test

Interfacial fatigue stress in PVD TiN coated tool steels under rolling contact fatigue conditions

NARCIS (Netherlands)

Carvalho, N.J.M.; Huis in ’t Veld, A.J.; Hosson, J.Th. De

1998-01-01

Titanium–nitrogen (TiN) films were Physical Vapour Deposited (PVD) on tool steel substrates with different hardness and surface roughness, in a Bai 640R unit using a triode ion plating (e-gun) with a high plasma density. The coated substrates were submitted to a rolling contact fatigue test

Effect of cerium and lanthanum on the microstructure and mechanical properties of AISI D2 tool steel

Energy Technology Data Exchange (ETDEWEB)

Hamidzadeh, Mohammad Ali, E-mail: mahamidzadeh@yahoo.com [Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111 (Iran, Islamic Republic of); Meratian, Mahmood; Saatchi, Ahmad [Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111 (Iran, Islamic Republic of)

2013-06-01

AISI D2 tool steel has excellent wear resistance with high dimensional stability. This type of steel is suitable for making molds. This paper describes investigations into the effect of adding Ce/La on microstructure of AISI D2 type cold work tool steels obtained by means of optical microscopy, scanning electron microscopy, X-ray diffraction, energy dispersive X-ray spectrometry (EDS) and image analyzer. The results showed that after modification with Ce/La, the morphology, size and distribution of M{sub 7}C{sub 3} carbides change greatly. The carbide network tends to break, and all carbides are refined and distributed homogeneously in the matrix, and also reduce the size of chromium carbides and increase the dissolution of carbides during heat treatment. The results of mechanical tests show that the toughness of the alloy increased about 75% without reducing the hardness of the alloy.

Improvement of strength and toughness of SKD11 type cold work tool steel; SKD 11 gata reikan koguko no kyojinsei no kaizen

Energy Technology Data Exchange (ETDEWEB)

Fukaura, K.; Sunada, H.; Yokoyama, Y. [Himeji Inst. of Technology, Hyogo (Japan); Teramoto, K. [Himeji Inst. of Technology, Hyogo (Japan). Graduate School| Sanyo Special Steel Co. Ltd., Hyogo (Japan)

1998-03-01

Toughness and wear resistance are the factors which affect on the lifetime of cold work tool steels importantly. Generally, both properties show the contrary characteristics. The evaluation of tool steel materials has been carried out focusing on the strength and wear resistance mainly. However, owing to the rapid progress of recent plastic working techniques, usage environments are under the severe conditions more and more. Therefore, it is expected to develop the high reliable cold work tool steels which balanced with toughness including wear resistance. In this study, the strength and toughness of a newly developed 0.8C-8Cr cold work tool steel whose composition was controlled to suppress the precipitation of massive eutectic M7C3 carbides were investigated with reference to microstructure and were compared with conventional SKD11. The toughness was evaluated by the area under the stress-strain curve. As a result, it was clarified that the tensile strength of the newly developed steel designated as Mod. SKD 11 was about 400 MPa higher and the toughness was 1.8 times larger than that of SKD 11 throughout a wide range of tempering temperatures and so forth. 17 refs., 13 figs., 1 tab.

A New High-Speed, High-Cycle, Gear-Tooth Bending Fatigue Test Capability

Science.gov (United States)

Stringer, David B.; Dykas, Brian D.; LaBerge, Kelsen E.; Zakrajsek, Andrew J.; Handschuh, Robert F.

2011-01-01

A new high-speed test capability for determining the high cycle bending-fatigue characteristics of gear teeth has been developed. Experiments were performed in the test facility using a standard spur gear test specimens designed for use in NASA Glenn s drive system test facilities. These tests varied in load condition and cycle-rate. The cycle-rate varied from 50 to 1000 Hz. The loads varied from high-stress, low-cycle loads to near infinite life conditions. Over 100 tests were conducted using AISI 9310 steel spur gear specimen. These results were then compared to previous data in the literature for correlation. Additionally, a cycle-rate sensitivity analysis was conducted by grouping the results according to cycle-rate and comparing the data sets. Methods used to study and verify load-path and facility dynamics are also discussed.

The influence of drawing speed on structure changes in high carbon steel wires

Directory of Open Access Journals (Sweden)

M. Suliga

2015-01-01

Full Text Available In the paper the influence of the drawing speed on structure changes has been assessed. The Scanning Electron Microscope investigation confirmed that for wires drawn with high total draft, exceeding 80 %, makes it impossible to clearly assess the impact of drawing technology on structural changes in the drawn wires. Thus, to assess the structural changes necessary to apply quantitative methods. On the basis of examination of the wire structure by measuring of electrical resistance, the structure changes in drawn wires has been determined. It has been shown that the increase of drawing speed, especially above 15 m/s, causes an increase in structure defect, with a decline in platelet orientation of cementite in drawn wires.

High Power Picosecond Laser Surface Micro-texturing of H13 Tool Steel and Pattern Replication onto ABS Plastics via Injection Moulding

Science.gov (United States)

Otanocha, Omonigho B.; Li, Lin; Zhong, Shan; Liu, Zhu

2016-03-01

H13 tool steels are often used as dies and moulds for injection moulding of plastic components. Certain injection moulded components require micro-patterns on their surfaces in order to modify the physical properties of the components or for better mould release to reduce mould contamination. With these applications it is necessary to study micro-patterning to moulds and to ensure effective pattern transfer and replication onto the plastic component during moulding. In this paper, we report an investigation into high average powered (100 W) picosecond laser interactions with H13 tool steel during surface micro-patterning (texturing) and the subsequent pattern replication on ABS plastic material through injection moulding. Design of experiments and statistical modelling were used to understand the influences of laser pulse repetition rate, laser fluence, scanning velocity, and number of scans on the depth of cut, kerf width and heat affected zones (HAZ) size. The characteristics of the surface patterns are analysed. The process parameter interactions and significance of process parameters on the processing quality and efficiency are characterised. An optimum operating window is recommended. The transferred geometry is compared with the patterns generated on the dies. A discussion is made to explain the characteristics of laser texturing and pattern replication on plastics.

Heat Treatment Optimization and Properties Correlation for H11-Type Hot-Work Tool Steel

Science.gov (United States)

Podgornik, B.; Puš, G.; Žužek, B.; Leskovšek, V.; Godec, M.

2018-02-01

The aim of this research was to determine the effect of vacuum-heat-treatment process parameters on the material properties and their correlations for low-Si-content AISI H11-type hot-work tool steel using a single Circumferentially Notched and fatigue Pre-cracked Tensile Bar (CNPTB) test specimen. The work was also focused on the potential of the proposed approach for designing advanced tempering diagrams and optimizing the vacuum heat treatment and design of forming tools. The results show that the CNPTB specimen allows a simultaneous determination and correlation of multiple properties for hot-work tool steels, with the compression and bending strength both increasing with hardness, and the strain-hardening exponent and bending strain increasing with the fracture toughness. On the other hand, the best machinability and surface quality of the hardened hot-work tool steel are obtained for hardness values between 46 and 50 HRC and a fracture toughness below 60 MPa√m.

High-speed imaging of blood splatter patterns

Energy Technology Data Exchange (ETDEWEB)

McDonald, T.E.; Albright, K.A.; King, N.S.P.; Yates, G.J. (Los Alamos National Lab., NM (United States)); Levine, G.F. (California Dept. of Justice, Sacramento, CA (United States). Bureau of Forensic Services)

1993-01-01

The interpretation of blood splatter patterns is an important element in reconstructing the events and circumstances of an accident or crime scene. Unfortunately, the interpretation of patterns and stains formed by blood droplets is not necessarily intuitive and study and analysis are required to arrive at a correct conclusion. A very useful tool in the study of blood splatter patterns is high-speed photography. Scientists at the Los Alamos National Laboratory, Department of Energy (DOE), and Bureau of Forensic Services, State of California, have assembled a high-speed imaging system designed to image blood splatter patterns. The camera employs technology developed by Los Alamos for the underground nuclear testing program and has also been used in a military mine detection program. The camera uses a solid-state CCD sensor operating at approximately 650 frames per second (75 MPixels per second) with a microchannel plate image intensifier that can provide shuttering as short as 5 ns. The images are captured with a laboratory high-speed digitizer and transferred to an IBM compatible PC for display and hard copy output for analysis. The imaging system is described in this paper.

High-speed imaging of blood splatter patterns

Energy Technology Data Exchange (ETDEWEB)

McDonald, T.E.; Albright, K.A.; King, N.S.P.; Yates, G.J. [Los Alamos National Lab., NM (United States); Levine, G.F. [California Dept. of Justice, Sacramento, CA (United States). Bureau of Forensic Services

1993-05-01

The interpretation of blood splatter patterns is an important element in reconstructing the events and circumstances of an accident or crime scene. Unfortunately, the interpretation of patterns and stains formed by blood droplets is not necessarily intuitive and study and analysis are required to arrive at a correct conclusion. A very useful tool in the study of blood splatter patterns is high-speed photography. Scientists at the Los Alamos National Laboratory, Department of Energy (DOE), and Bureau of Forensic Services, State of California, have assembled a high-speed imaging system designed to image blood splatter patterns. The camera employs technology developed by Los Alamos for the underground nuclear testing program and has also been used in a military mine detection program. The camera uses a solid-state CCD sensor operating at approximately 650 frames per second (75 MPixels per second) with a microchannel plate image intensifier that can provide shuttering as short as 5 ns. The images are captured with a laboratory high-speed digitizer and transferred to an IBM compatible PC for display and hard copy output for analysis. The imaging system is described in this paper.

Influence of pre-heating on the surface modification of powder-metallurgy processed cold-work tool steel during laser surface melting

Energy Technology Data Exchange (ETDEWEB)

Šturm, Roman, E-mail: roman.sturm@fs.uni-lj.si [University of Ljubljana, Faculty of Mechanical Engineering, Aškerčeva 6, 1000 Ljubljana (Slovenia); Štefanikova, Maria [University of Ljubljana, Faculty of Mechanical Engineering, Aškerčeva 6, 1000 Ljubljana (Slovenia); Steiner Petrovič, Darja [Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana (Slovenia)

2015-01-15

Graphical abstract: - Highlights: • Heat-treatment protocol for laser surface melting of cold-work tool steel is proposed. • The laser melted steel surface is hardened, and morphologically modified. • The pre-heating of substrate creates a crack-and pore-free steel surface. • The optimum pre-heating temperature is determined to be 350 °C. • Using pre-heating the quantity of retained austenite is reduced. - Abstract: In this study we determine the optimal parameters for surface modification using the laser surface melting of powder-metallurgy processed, vanadium-rich, cold-work tool steel. A combination of steel pre-heating, laser surface melting and a subsequent heat treatment creates a hardened and morphologically modified surface of the selected high-alloy tool steel. The pre-heating of the steel prior to the laser surface melting ensures a crack- and pore-free modified surface. Using a pre-heating temperature of 350 °C, the extremely fine microstructure, which typically evolves during the laser-melting, became slightly coarser and the volume fraction of retained austenite was reduced. In the laser-melted layer the highest values of microhardness were achieved in the specimens where a subsequent heat treatment at 550 °C was applied. The performed thermodynamic calculations were able to provide a very valuable assessment of the liquidus temperature and, especially, a prediction of the chemical composition as well as the precipitation and dissolution sequence for the carbides.

Hardness of H13 Tool Steel After Non-isothermal Tempering

Science.gov (United States)

Nelson, E.; Kohli, A.; Poirier, D. R.

2018-04-01

A direct method to calculate the tempering response of a tool steel (H13) that exhibits secondary hardening is presented. Based on the traditional method of presenting tempering response in terms of isothermal tempering, we show that the tempering response for a steel undergoing a non-isothermal tempering schedule can be predicted. Experiments comprised (1) isothermal tempering, (2) non-isothermal tempering pertaining to a relatively slow heating to process-temperature and (3) fast-heating cycles that are relevant to tempering by induction heating. After establishing the tempering response of the steel under simple isothermal conditions, the tempering response can be applied to non-isothermal tempering by using a numerical method to calculate the tempering parameter. Calculated results are verified by the experiments.

To Enhance the Fire Resistance Performance of High-Speed Steel Roller Door with Water Film System

Directory of Open Access Journals (Sweden)

De-Hua Chung

2015-01-01

Full Text Available The structure of high-speed roller door with water film has improved in this study. The flameproof water film system is equipped with a water circulating device to reduce the water consumption of water film system. The water film is generated at the roller box of the high-speed roller door in this study. The heating test is done with the full-scale heating furnace. Both cases of the water film on unexposed surface and water film on exposed surface passed the fire resistance test based on ISO 834, proving that the high-speed roller door with water film system has 120A fire resistance period. The main findings indicate that the water film on exposed surface shows that as the amount of water film evaporated by high temperature inside the furnace must be greater than the evaporation capacity of water film on unexposed surface, the required water supply is 660 L more than the water film on unexposed surface.

High speed ultrasonic system to measure bubbles velocities in a horizontal two-phase flow

International Nuclear Information System (INIS)

Cunha Filho, Jurandyr S.; Jian Su; Farias, Marcos S.; Faccini, Jose L.H.; Lamy, Carlos A.

2009-01-01

In this work, a non invasive technique consisting of a high speed ultrasonic multitransducer pulse-echo system was developed to characterize gas-liquid two-phase flow parameters that are important in the study of the primary refrigeration circuit of nuclear reactors. The high speed ultrasonic system consists of two transducers (10 MHz/φ 6.35 mm), a generator/multiplexer board, and software that selects and has a data acquisition system of the ultrasonic signals. The resolutions of the system and the pulse time generated from each transducer are, respectively, 10 ns and 1.06 ms. The system initially was used in the local instantaneous measurement of gas-liquid interface in a circular horizontal pipe test section made of a 5 m long stainless steel pipe of 51.2 mm inner diameter, where the elongated bubbles velocity was measured (Taylor bubbles). The results show that the high speed ultrasonic pulse-echo system provides good results for the determination of elongated bubbles velocities. (author)

Joint punching and frequency effects on practical magnetic characteristics of electrical steels for high-speed machines

Science.gov (United States)

Kedous-Lebouc, A.; Messal, O.; Youmssi, A.

2017-03-01

Mechanical punching of electrical steels causes a degradation of their magnetic characteristics which can extend several millimeters from the cut edge. So, in the field of industrial applications, particularly that of small electrical machines, the stator core made of rigid and thin teeth would be subject to more losses. Thus, this topic of the effect of punching has to be submitted to further deep characterization and development in order to give some insight into the different mechanisms. In this framework, this paper evaluates the combined effect of punching and frequency on the magnetization curve and iron losses in thin SiFe and CoFe soft magnetic sheets. These alloys are typically suitable for the manufacture of high-speed electrical machines used in on board applications (aircraft power generators, automotive, etc). Two SiFe alloys and a CoFe alloy have been investigated. First, different rectangular samples of variable width (15, 10, 5, 3 mm) have been industrially punched. Then, a dedicated magnetic characterization has been made, using basically a mini-Epstein frame. Measurements have been performed from 50 Hz to 1 kHz and from 0.3 T to near saturation. Both rolling and transverse directions have been considered. Finally, a first attempt to predict the degradation due to the punching is presented. A useful description of the magnetic permeability as a function of B and f is given and the degradation parameters are estimated based on the knowledge of the reference permeability.

Joint punching and frequency effects on practical magnetic characteristics of electrical steels for high-speed machines

Energy Technology Data Exchange (ETDEWEB)

Kedous-Lebouc, A. [Univ. Grenoble Alpes, G2Elab, F-38000 Grenoble, France — CNRS, G2Elab, F-38000 Grenoble (France); Messal, O., E-mail: oualid.messal@g2elab.grenoble-inp.fr [Univ. Grenoble Alpes, G2Elab, F-38000 Grenoble, France — CNRS, G2Elab, F-38000 Grenoble (France); Youmssi, A. [Université de N’gaoundéré, BP. 455 N’Gaoundéré (Cameroon)

2017-03-15

Mechanical punching of electrical steels causes a degradation of their magnetic characteristics which can extend several millimeters from the cut edge. So, in the field of industrial applications, particularly that of small electrical machines, the stator core made of rigid and thin teeth would be subject to more losses. Thus, this topic of the effect of punching has to be submitted to further deep characterization and development in order to give some insight into the different mechanisms. In this framework, this paper evaluates the combined effect of punching and frequency on the magnetization curve and iron losses in thin SiFe and CoFe soft magnetic sheets. These alloys are typically suitable for the manufacture of high-speed electrical machines used in on board applications (aircraft power generators, automotive, etc). Two SiFe alloys and a CoFe alloy have been investigated. First, different rectangular samples of variable width (15, 10, 5, 3 mm) have been industrially punched. Then, a dedicated magnetic characterization has been made, using basically a mini-Epstein frame. Measurements have been performed from 50 Hz to 1 kHz and from 0.3 T to near saturation. Both rolling and transverse directions have been considered. Finally, a first attempt to predict the degradation due to the punching is presented. A useful description of the magnetic permeability as a function of B and f is given and the degradation parameters are estimated based on the knowledge of the reference permeability.

Microstructural Evolution during DPRM Process of Semisolid Ledeburitic D2 Tool Steel

OpenAIRE

M. N. Mohammed; M. Z. Omar; J. Syarif; Z. Sajuri; M. S. Salleh; K. S. Alhawari

2013-01-01

Semisolid metal processing is a relatively new technology that offers several advantages over liquid processing and solid processing because of the unique behaviour and characteristic microstructure of metals in this state. With the aim of finding a minimum process chain for the manufacture of high-quality production at minimal cost for forming, the microstructural evolution of the ledeburitic AISI D2 tool steel in the semisolid state was studied experimentally. The potential of the direct pa...

Tool steel quality and surface finishing of plastic molds

Directory of Open Access Journals (Sweden)

Rafael Agnelli Mesquita

2010-01-01

Full Text Available Plastic industry is today in a constant growth, demanding several products from other segments, which includes the plastic molds, mainly used in the injection molding process. Considering all the requirements of plastic molds, the surface finishing is of special interest, as the injected plastic part is able to reproduce any details (and also defects from the mold surface. Therefore, several aspects on mold finishing are important, mainly related to manufacturing conditions - machining, grinding, polishing and texturing, and also related to the tool steel quality, in relation to microstructure homogeneity and non-metallic inclusions (cleanliness. The present paper is then focused on this interrelationship between steel quality and manufacturing process, which are both related to the final quality of plastic mold surfaces. Examples are discussed in terms of surface finishing of plastic molds and the properties or the microstructure of mold steels.

Development of new high-performance stainless steels

International Nuclear Information System (INIS)

Park, Yong Soo

2002-01-01

This paper focused on high-performance stainless steels and their development status. Effect of nitrogen addition on super-stainless steel was discussed. Research activities at Yonsei University, on austenitic and martensitic high-performance stainless, steels, and the next-generation duplex stainless steels were introduced

On high temperature strength of carbon steels

International Nuclear Information System (INIS)

Ichinose, Hiroyuki; Tamura, Manabu; Kanero, Takahiro; Ihara, Yoshihito

1977-01-01

In the steels for high temperature use, the oxidation resistance is regarded as important, but carbon steels show enough oxidation resistance to be used continuously at the temperature up to 500 deg. C if the strength is left out of consideration, and up to 450 deg. C even when the strength is taken into account. Moreover, the production is easy, the workability and weldability are good, and the price is cheap in carbon steels as compared with alloy steels. In the boilers for large thermal power stations, 0.15-0.30% C steels are used for reheater tubes, main feed water tubes, steam headers, wall water tubes, economizer tubes, bypass pipings and others, and they account for 70% of all steel materials used for the boilers of 350 MW class and 30% in 1000 MW class. The JIS standard for the carbon steels for high temperature use and the related standards in foreign countries are shown. The high temperature strength of carbon steels changes according to the trace elements, melting and heat treatment as well as the main compositions of C, Si and Mn. Al and N affect the high temperature strength largely. The characteristics of carbon steels after the heating for hours, the factors controlling the microstructure and high temperature strength, and the measures to improve the high temperature strength of carbon steels are explained. (Kako, I.)

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process

Directory of Open Access Journals (Sweden)

N. V. Dhandapani

2015-01-01

Full Text Available This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results.

Investigation on Effect of Material Hardness in High Speed CNC End Milling Process.

Science.gov (United States)

Dhandapani, N V; Thangarasu, V S; Sureshkannan, G

2015-01-01

This research paper analyzes the effects of material properties on surface roughness, material removal rate, and tool wear on high speed CNC end milling process with various ferrous and nonferrous materials. The challenge of material specific decision on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate, cutting tool material, and type of coating for the cutting tool for required quality and quantity of production is addressed. Generally, decision made by the operator on floor is based on suggested values of the tool manufacturer or by trial and error method. This paper describes effect of various parameters on the surface roughness characteristics of the precision machining part. The prediction method suggested is based on various experimental analysis of parameters in different compositions of input conditions which would benefit the industry on standardization of high speed CNC end milling processes. The results show a basis for selection of parameters to get better results of surface roughness values as predicted by the case study results.

Application and validation of the notch master curve in medium and high strength structural steels

Energy Technology Data Exchange (ETDEWEB)

Cicero, Sergio; Garcia, Tiberio [Universidad de Cantabria, Santander (Spain); Madrazo, Virginia [PCTCAN, Santander (Spain)

2015-10-15

This paper applies and validates the Notch master curve in two ferritic steels with medium (steel S460M) and high (steel S690Q) strength. The Notch master curve is an engineering tool that allows the fracture resistance of notched ferritic steels operating within their corresponding ductile-to-brittle transition zone to be estimated. It combines the Master curve and the Theory of critical distances in order to take into account the temperature and the notch effect respectively, assuming that both effects are independent. The results, derived from 168 fracture tests on notched specimens, demonstrate the capability of the Notch master curve for the prediction of the fracture resistance of medium and high strength ferritic steels operating within their ductile-to-brittle transition zone and containing notches.

Service behaviour of high speed steel rolling rolls used in hot strip mills; Comportamiento en servicio de los aceros rapidos utilizados en la fabricacion de los cilindros de trabajo de los trenes de bandas en caliente

Energy Technology Data Exchange (ETDEWEB)

Ziadi, A.; Belzunce, F. J.; Rodriguez, C.; Fernandez, I.

2005-07-01

Work rolls used in hot strip mills may be able to carry out severe actions: very high thermal stresses and wear, along with mechanical stresses due to normal rolling loads, which develop in the presence of cracks, produced by the former actions. The microstructure and the mechanical behaviour (strength and toughness) of high speed steels, which recently have been introduced in this applications, were studied in this work in comparison with high chromium cast irons. (Author) 7 refs.

Experimental Investigation of Surface Layer Properties of High Thermal Conductivity Tool Steel after Electrical Discharge Machining

Directory of Open Access Journals (Sweden)

Rafał Świercz

2017-12-01

Full Text Available New materials require the use of advanced technology in manufacturing complex shape parts. One of the modern materials widely used in the tool industry for injection molds or hot stamping dies is high conductivity tool steel (HTCS 150. Due to its hardness (55 HRC and thermal conductivity at 66 W/mK, this material is difficult to machine by conventional treatment and is being increasingly manufactured by nonconventional technology such as electrical discharge machining (EDM. In the EDM process, material is removed from the workpiece by a series of electrical discharges that cause changes to the surface layers properties. The final state of the surface layer directly influences the durability of the produced elements. This paper presents the influence of EDM process parameters: discharge current Ic and the pulse time ton on surface layer properties. The experimental investigation was carried out with an experimental methodology design. Surface layers properties including roughness 3D parameters, the thickness of the white layer, heat affected zone, tempered layer and occurring micro cracks were investigated and described. The influence of the response surface methodology (RSM of discharge current Ic and the pulse time ton on the thickness of the white layer and roughness parameters Sa, Sds and Ssc were described and established.

Effect of Low Nickel Dopant on Torque Transducer Response Function in High-Chromium Content ESR Stainless Tool Steels

Science.gov (United States)

Wiewel, Joseph L.; Hecox, Bryan G.; Orris, Jason T.; Boley, Mark S.

2007-03-01

The change in magnetoelastic torque transducer response was investigated as a low nickel content (up to 0.2%) is alloyed into an ESR (Electro-Slag-Refining) stainless tool steel with a chromium content of around 13%, which our previous studies have proven to be the ideal level of chromium content for optimal transducer performance. Two separate hollow steel 3/4-inch diameter shafts were prepared from ESR 416 and ESR 420 steel, respectively, the first having no nickel content and the second having 0.2% nickel content. The heat treatment of these steels consisted of a hardening process conducted in a helium atmosphere at 1038^oC, followed by an annealing at 871^oC for 5h and a 15^oC cool down rate. Prior and subsequent to the heat treatment processes, the circumferential and axial magnetic hysteresis properties of the samples were measured and their external field signals were mapped over the magnetically polarized regions both with and without applied shear stress up to 2500 psi on the samples. It was found that the effect of the low nickel dopant was to improve torque transducer sensitivity and linearity, but heat treatment worsened the performance of both samples.

Ductility of high chromium stainless steels

International Nuclear Information System (INIS)

Peretyat'ko, V.N.; Kazantsev, A.A.

1997-01-01

Aimed to optimize the hot working conditions for high chromium stainless steels the experiments were carried in the temperature range of 800-1300 deg C using hot torsion tests and cylindrical specimens of ferritic and ferritic-martensitic steels 08Kh13, 12Kh13, 20Kh13, 30Kh13 and 40Kh13. Testing results showed that steel plasticity varies in a wide range depending on carbon content. Steels of lesser carbon concentration (08Kh13 and 12Kh13) exhibit a sharp increase in plasticity with a temperature rise, especially in the interval of 1200-1250 deg C. Steels 20Kh13 and 30Kh13 display insignificant plasticity increasing, whereas plastic properties of steel 40Kh13 increase noticeably in the range of 1000-1300 deg C. It is shown that optimal hot working conditions for specific steel must be selected with account of steel phase composition at high temperatures

High temperature oxidation behavior of ODS steels

Science.gov (United States)

Kaito, T.; Narita, T.; Ukai, S.; Matsuda, Y.

2004-08-01

Oxide dispersion strengthened (ODS) steels are being developing for application as advanced fast reactor cladding and fusion blanket materials, in order to allow increased operation temperature. Oxidation testing of ODS steel was conducted under a controlled dry air atmosphere to evaluate the high temperature oxidation behavior. This showed that 9Cr-ODS martensitic steels and 12Cr-ODS ferritic steels have superior high temperature oxidation resistance compared to 11 mass% Cr PNC-FMS and 17 mass% Cr ferritic stainless steel. This high temperature resistance is attributed to earlier formation of the protective α-Cr 2O 3 on the outer surface of ODS steels.

Investigation of Microstructure and Mechanical Properties in Hot-work Tool Steels

OpenAIRE

Rey, Tomas

2017-01-01

Hot-work tool steels make up an important group of steels that are able to perform with good strength and toughness properties at elevated temperatures and stresses. They are able to gain this behavior through their alloy composition and heat treatment, which relies on the precipitation of alloy carbides to counter the loss in strength as the tempered material becomes more ductile. As demand grows for materials that are suitable for even harsher applications and that show improved mechanical ...

The Study on Weldability of Boron Steel and Hot-Stamped Steel by Using Laser Heat Source (Ⅲ) - Comparison on Laser Weldability of Boron Steel and Hot -Stamped Steel-

Energy Technology Data Exchange (ETDEWEB)

Choi, So Young; Kim, Jong Do [Korea Maritime and Ocean University, Busan (Korea, Republic of); Kim, Jong Su [Korea Institute of Machinery and Materials, Daejeon (Korea, Republic of)

2015-01-15

This study was conducted to compare the laser weldability of boron steel and hot-stamped steel. In general, boron steel is used in the hot-stamping process. Hot-stamping is a method for simultaneously forming and cooling boron steel in a press die after heating it to the austenitizing temperature. Hot-stamped steel has a strength of 1500 MPa or more. Thus, in this study, the laser weldability of boron steel and that of hot-stamped steel were investigated and compared. A continuous wave disk laser was used to produce butt and lap joints. In the butt welding, the critical cooling speed at which full penetration was obtained in the hot-stamped steel was lower than that of boron steel. In the lap welding, the joint widths were similar regardless of the welding speed when full penetration was obtained.

The Study on Weldability of Boron Steel and Hot-Stamped Steel by Using Laser Heat Source (Ⅲ) - Comparison on Laser Weldability of Boron Steel and Hot -Stamped Steel-

International Nuclear Information System (INIS)

Choi, So Young; Kim, Jong Do; Kim, Jong Su

2015-01-01

This study was conducted to compare the laser weldability of boron steel and hot-stamped steel. In general, boron steel is used in the hot-stamping process. Hot-stamping is a method for simultaneously forming and cooling boron steel in a press die after heating it to the austenitizing temperature. Hot-stamped steel has a strength of 1500 MPa or more. Thus, in this study, the laser weldability of boron steel and that of hot-stamped steel were investigated and compared. A continuous wave disk laser was used to produce butt and lap joints. In the butt welding, the critical cooling speed at which full penetration was obtained in the hot-stamped steel was lower than that of boron steel. In the lap welding, the joint widths were similar regardless of the welding speed when full penetration was obtained

The problems of high-nitrogen steels production

International Nuclear Information System (INIS)

Svyazhin, A.G.; Kaputkina, L.M.; Efimenko, S.P.

1999-01-01

Analysis of existing technologies of high-nitrogen steel production shows that rational nitrogen content in mass production corresponds to moderate high values. Such steels can be smelted under normal or slightly elevated pressure in steelmaking units, using processes of mass- and special metallurgy. High-nitrogen steels with ''overequilibrium'' nitrogen content are promising, but technology and equipment for production of them are complicated, and production of such steels is therefore limited. (orig.)

TECHNOLOGICAL ADVANCEMENT OF DEPOSIT WELDING AND GAS LASER CUTTING TO INCREASE THE EFFICIENCY OF THE BIMETALLIC TOOL PRODUCTION

Directory of Open Access Journals (Sweden)

Burlachenko Oleg Vasil’evich

2017-08-01

Full Text Available Deposit welding is the application of a layer of metal on the surface of a product using fusion welding. In this paper, we consider the method of improving the technology of gas laser cutting, which makes it possible to achieve a high productivity of manufacturing a bimetallic tool. The present paper is concerned with the advantages of gas laser cutting which allows to consider this particular process of separating materials as highly-productive, low-waste, and advanced method of removing allowances of weld-deposit high-speed steel on the working surfaces of bimetallic tool. Urgency of the use of deposit welding and gas laser cutting to improve the efficiency of production of bimetallic tool is shown. The comparative analysis of gas-laser cutting and other cutting methods is given according to the geometrical parameters of cutting and surface quality. Analysis of the results of experimental studies has confirmed the high technological attractiveness and economic efficiency of manufacturing composite structures of punches and matrices when applying deposit welding of cutting parts with high-speed steels. The cost of dimensional processing of the welded cutting part is reduced by 4 to 6 times, while the manufacturing time is reduced by 6 to 12 times.

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Science.gov (United States)

Almoussawi, M.; Smith, A. J.

2018-03-01

Poly Crystalline Boron Nitride (PCBN) tool wear during the friction stir welding of high melting alloys is an obstacle to commercialize the process. This work simulates the friction stir welding process and tool wear during the plunge/dwell period of 14.8 mm EH46 thick plate steel. The Computational Fluid Dynamic (CFD) model was used for simulation and the wear of the tool is estimated from temperatures and shear stress profile on the tool surface. Two sets of tool rotational speeds were applied including 120 and 200 RPM. Seven plunge/dwell samples were prepared using PCBN FSW tool, six thermocouples were also embedded around each plunge/dwell case in order to record the temperatures during the welding process. Infinite focus microscopy technique was used to create macrographs for each case. The CFD result has been shown that a shear layer around the tool shoulder and probe-side denoted as thermo-mechanical affected zone (TMAZ) was formed and its size increase with tool rotational speed increase. Maximum peak temperature was also found to increase with tool rotational speed increase. PCBN tool wear under shoulder was found to increase with tool rotational speed increase as a result of tool's binder softening after reaching to a peak temperature exceeds 1250 °C. Tool wear also found to increase at probe-side bottom as a result of high shear stress associated with the decrease in the tool rotational speed. The amount of BN particles revealed by SEM in the TMAZ were compared with the CFD model.

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Science.gov (United States)

Almoussawi, M.; Smith, A. J.

2018-05-01

Poly Crystalline Boron Nitride (PCBN) tool wear during the friction stir welding of high melting alloys is an obstacle to commercialize the process. This work simulates the friction stir welding process and tool wear during the plunge/dwell period of 14.8 mm EH46 thick plate steel. The Computational Fluid Dynamic (CFD) model was used for simulation and the wear of the tool is estimated from temperatures and shear stress profile on the tool surface. Two sets of tool rotational speeds were applied including 120 and 200 RPM. Seven plunge/dwell samples were prepared using PCBN FSW tool, six thermocouples were also embedded around each plunge/dwell case in order to record the temperatures during the welding process. Infinite focus microscopy technique was used to create macrographs for each case. The CFD result has been shown that a shear layer around the tool shoulder and probe-side denoted as thermo-mechanical affected zone (TMAZ) was formed and its size increase with tool rotational speed increase. Maximum peak temperature was also found to increase with tool rotational speed increase. PCBN tool wear under shoulder was found to increase with tool rotational speed increase as a result of tool's binder softening after reaching to a peak temperature exceeds 1250 °C. Tool wear also found to increase at probe-side bottom as a result of high shear stress associated with the decrease in the tool rotational speed. The amount of BN particles revealed by SEM in the TMAZ were compared with the CFD model.

Study on the separation effect of high-speed ultrasonic vibration cutting.

Science.gov (United States)

Zhang, Xiangyu; Sui, He; Zhang, Deyuan; Jiang, Xinggang

2018-07-01

High-speed ultrasonic vibration cutting (HUVC) has been proven to be significantly effective when turning Ti-6Al-4V alloy in recent researches. Despite of breaking through the cutting speed restriction of the ultrasonic vibration cutting (UVC) method, HUVC can also achieve the reduction of cutting force and the improvements in surface quality and cutting efficiency in the high-speed machining field. These benefits all result from the separation effect that occurs during the HUVC process. Despite the fact that the influences of vibration and cutting parameters have been discussed in previous researches, the separation analysis of HUVC should be conducted in detail in real cutting situations, and the tool geometry parameters should also be considered. In this paper, three situations are investigated in details: (1) cutting without negative transient clearance angle and without tool wear, (2) cutting with negative transient clearance angle and without tool wear, and (3) cutting with tool wear. And then, complete separation state, partial separation state and continuous cutting state are deduced according to real cutting processes. All the analysis about the above situations demonstrate that the tool-workpiece separation will take place only if appropriate cutting parameters, vibration parameters, and tool geometry parameters are set up. The best separation effect was obtained with a low feedrate and a phase shift approaching 180 degrees. Moreover, flank face interference resulted from the negative transient clearance angle and tool wear contributes to an improved separation effect that makes the workpiece and tool separate even at zero phase shift. Finally, axial and radial transient cutting force are firstly obtained to verify the separation effect of HUVC, and the cutting chips are collected to weigh the influence of flank face interference. Copyright © 2018 Elsevier B.V. All rights reserved.

Process Optimization of EDM Cutting Process on Tool Steel using Zinc Coated Electrode

Directory of Open Access Journals (Sweden)

Hanizam H.

2017-01-01

Full Text Available In WEDM machining process, surface finish quality depends on intensity and duration of spark plasma. Electrode wire diameter has significant effect on the spark intensity and yet the studies on this matter still less. Therefore, the main objectives of this studies are to compare the different diameters of zinc coated and uncoated brass electrode on H13 tool steel surface roughness. The experiments were conducted on Sodick VZ300L WEDM and work piece material of tool steel AISI H13 block. Electrode of zinc coated brass with diameters of 0.1 mm, 0.2 mm, 0.25 mm and uncoated brass 0.2 mm were used. The surface roughness of cutting was measured using the SUR-FTEST SJ-410 Mitutoyo, surface roughness tester. The results suggest that better surface roughness quality can be achieved through smaller electrode wire diameter. The zinc coated improves flushing ability and sparks intensity resulting in better surface finish of H13 tool steel. New alloys and coating materials shall be experimented to optimized the process further.

Effect of process parameters on optimum welding condition of DP590 steel by friction stir welding

Energy Technology Data Exchange (ETDEWEB)

Kim, Young Gon; Kim, Ji Sun; Kim, In Ju [Korea Institute of Industrial Technology, Gwangju (Korea, Republic of)

2014-12-15

In the automotive industry, vehicle weight reduction techniques have been actively studied to improve the rate of fuel consumption and to cope with the regulation restricting exhaust gas. For this reason, advanced high-strength steel (AHSS) is preferred in the automobile industry as its tensile strength is 590 MPa and over. In this study, to obtain the optimum welding condition, the friction stir welding (FSW) process applied to AHSS was considered. The FSW experiment was performed on a stir plate using a Si{sub 3}N{sub 4} tool and a 1.4-mm thick DP590 steel sheet manufactured by cold rolling. In addition, to investigate the temperature distribution of the advancing and retreating sides in the welding state, the tool rotation speed of 800 rpm, and the welding speed of 180 mm/min, a K-type thermocouple was inserted in the backing plate, and the peak temperature was evaluated at each point. Especially, the correlation between the heat input per unit length and the formation of the FSW zone was minutely analyzed.

Effect of process parameters on optimum welding condition of DP590 steel by friction stir welding

International Nuclear Information System (INIS)

Kim, Young Gon; Kim, Ji Sun; Kim, In Ju

2014-01-01

In the automotive industry, vehicle weight reduction techniques have been actively studied to improve the rate of fuel consumption and to cope with the regulation restricting exhaust gas. For this reason, advanced high-strength steel (AHSS) is preferred in the automobile industry as its tensile strength is 590 MPa and over. In this study, to obtain the optimum welding condition, the friction stir welding (FSW) process applied to AHSS was considered. The FSW experiment was performed on a stir plate using a Si 3 N 4 tool and a 1.4-mm thick DP590 steel sheet manufactured by cold rolling. In addition, to investigate the temperature distribution of the advancing and retreating sides in the welding state, the tool rotation speed of 800 rpm, and the welding speed of 180 mm/min, a K-type thermocouple was inserted in the backing plate, and the peak temperature was evaluated at each point. Especially, the correlation between the heat input per unit length and the formation of the FSW zone was minutely analyzed.

The Applicability of Taylor’s Model to the Drilling of CFRP Using Uncoated WC-Co Tools: The Influence of Cutting Speed on Tool Wear

OpenAIRE

Merino Perez, J.L.; Merson, E.; Ayvar-Soberanis, S.; Hodzic, A.

2014-01-01

This work investigates the applicability of Taylor’s model on the drilling of CFRP using uncoated WC-Co tools, by assessing the influence of cutting speed (Vc) on tool wear. Two different resins, possessing low and high glass transition temperatures (Tg), and two different reinforcements, high strength and high modulus woven fabrics, were combined into three different systems. Flank wear rate gradient exhibited to be more reinforcement dependent, while the actual flank wear rate showed to be ...

Effect of current and travel speed variation of TIG welding on microstructure and hardness of stainless steel SS 316L

Science.gov (United States)

Jatimurti, Wikan; Abdillah, Fakhri Aulia; Kurniawan, Budi Agung; Rochiem, Rochman

2018-04-01

One of the stainless steel types that widely used in industry is SS 316L, which is austenitic stainless steel. One of the welding methods to join stainless steel is Tungsten Inert Gas (TIG), which can affect its morphology, microstructure, strength, hardness, and even lead to cracks in the weld area due to the given heat input. This research has a purpose of analyzing the relationship between microstructure and hardness value of SS 316L stainless steel after TIG welding with the variation of current and travel speed. The macro observation shows a distinct difference in the weld metal and base metal area, and the weld form is not symmetrical. The metallographic test shows the phases that formed in the specimen are austenite and ferrite, which scattered in three welding areas. The hardness test showed that the highest hardness value found in the variation of travel speed 12 cm/min with current 100 A. Welding process and variation were given do not cause any defects in the microstructure, such as carbide precipitation and sigma phase, means that it does not affect the hardness and corrosion resistance of all welded specimen.

Microstructure and Mechanical Properties of Laser Clad and Post-cladding Tempered AISI H13 Tool Steel

Science.gov (United States)

Telasang, Gururaj; Dutta Majumdar, Jyotsna; Wasekar, Nitin; Padmanabham, G.; Manna, Indranil

2015-05-01

This study reports a detailed investigation of the microstructure and mechanical properties (wear resistance and tensile strength) of hardened and tempered AISI H13 tool steel substrate following laser cladding with AISI H13 tool steel powder in as-clad and after post-cladding conventional bulk isothermal tempering [at 823 K (550 °C) for 2 hours] heat treatment. Laser cladding was carried out on AISI H13 tool steel substrate using a 6 kW continuous wave diode laser coupled with fiber delivering an energy density of 133 J/mm2 and equipped with a co-axial powder feeding nozzle capable of feeding powder at the rate of 13.3 × 10-3 g/mm2. Laser clad zone comprises martensite, retained austenite, and carbides, and measures an average hardness of 600 to 650 VHN. Subsequent isothermal tempering converted the microstructure into one with tempered martensite and uniform dispersion of carbides with a hardness of 550 to 650 VHN. Interestingly, laser cladding introduced residual compressive stress of 670 ± 15 MPa, which reduces to 580 ± 20 MPa following isothermal tempering. Micro-tensile testing with specimens machined from the clad zone across or transverse to cladding direction showed high strength but failure in brittle mode. On the other hand, similar testing with samples sectioned from the clad zone parallel or longitudinal to the direction of laser cladding prior to and after post-cladding tempering recorded lower strength but ductile failure with 4.7 and 8 pct elongation, respectively. Wear resistance of the laser surface clad and post-cladding tempered samples (evaluated by fretting wear testing) registered superior performance as compared to that of conventional hardened and tempered AISI H13 tool steel.

STRESS ANALYSIS IN CUTTING TOOLS COATED TiN AND EFFECT OF THE FRICTION COEFFICIENT IN TOOL-CHIP INTERFACE

Directory of Open Access Journals (Sweden)

Kubilay ASLANTAŞ

2003-02-01

Full Text Available The coated tools are regularly used in today's metal cutting industry. Because, it is well known that thin and hard coatings can reduce tool wear, improve tool life and productivity. Such coatings have significantly contributed to the improvements cutting economies and cutting tool performance through lower tool wear and reduced cutting forces. TiN coatings have especially high strength and low friction coefficients. During the cutting process, low friction coefficient reduce damage in cutting tool. In addition, maximum stress values between coating and substrate also decrease as the friction coefficient decreases. In the present study, stress analysis is carried out for HSS (High Speed Steel cutting tool coated with TiN. The effect of the friction coefficient between tool and chip on the stresses developed at the cutting tool surface and interface of coating and HSS is investigated. Damage zones during cutting process was also attempted to determine. Finite elements method is used for the solution of the problem and FRANC2D finite element program is selected for numerical solutions.

An investigation of laser cutting quality of 22MnB5 ultra high strength steel using response surface methodology

Science.gov (United States)

Tahir, Abdul Fattah Mohd; Aqida, Syarifah Nur

2017-07-01

In hot press forming, changes of mechanical properties in boron steel blanks have been a setback in trimming the final shape components. This paper presents investigation of kerf width and heat affected zone (HAZ) of ultra high strength 22MnB5 steel cutting. Sample cutting was conducted using a 4 kW Carbon Dioxide (CO2) laser machine with 10.6 μm wavelength with the laser spot size of 0.2 mm. A response surface methodology (RSM) using three level Box-Behnken design of experiment was developed with three factors of peak power, cutting speed and duty cycle. The parameters were optimised for minimum kerf width and HAZ formation. Optical evaluation using MITUTOYO TM 505 were conducted to measure the kerf width and HAZ region. From the findings, laser duty cycle was crucial to determine cutting quality of ultra-high strength steel; followed by cutting speed and laser power. Meanwhile, low power intensity with continuous wave contributes the narrowest kerf width formation and least HAZ region.

Machining of AISI D2 Tool Steel with Multiple Hole Electrodes by EDM Process

Science.gov (United States)

Prasad Prathipati, R.; Devuri, Venkateswarlu; Cheepu, Muralimohan; Gudimetla, Kondaiah; Uzwal Kiran, R.

2018-03-01

In recent years, with the increasing of technology the demand for machining processes is increasing for the newly developed materials. The conventional machining processes are not adequate to meet the accuracy of the machining of these materials. The non-conventional machining processes of electrical discharge machining is one of the most efficient machining processes is being widely used to machining of high accuracy products of various industries. The optimum selection of process parameters is very important in machining processes as that of an electrical discharge machining as they determine surface quality and dimensional precision of the obtained parts, even though time consumption rate is higher for machining of large dimension features. In this work, D2 high carbon and chromium tool steel has been machined using electrical discharge machining with the multiple hole electrode technique. The D2 steel has several applications such as forming dies, extrusion dies and thread rolling. But the machining of this tool steel is very hard because of it shard alloyed elements of V, Cr and Mo which enhance its strength and wear properties. However, the machining is possible by using electrical discharge machining process and the present study implemented a new technique to reduce the machining time using a multiple hole copper electrode. In this technique, while machining with multiple holes electrode, fin like projections are obtained, which can be removed easily by chipping. Then the finishing is done by using solid electrode. The machining time is reduced to around 50% while using multiple hole electrode technique for electrical discharge machining.

Development of Ferrium S53 High-Strength, Corrosion-Resistant Steel

Science.gov (United States)

2009-01-01

or any other high-strength steel. No special tools or grinding wheels are required. The only significant differences with S53 are  Machining... runout point and ** point) Fit for 4330 in Air (w/o runout points) Fit for S53 in Salt Fit for 300M in Salt Fit for 4330 in Salt MIL HNBK 5 for 300M in

Machining of high performance workpiece materials with CBN coated cutting tools

International Nuclear Information System (INIS)

Uhlmann, E.; Fuentes, J.A. Oyanedel; Keunecke, M.

2009-01-01

The machining of high performance workpiece materials requires significantly harder cutting materials. In hard machining, the early tool wear occurs due to high process forces and temperatures. The hardest known material is the diamond, but steel materials cannot be machined with diamond tools because of the reactivity of iron with carbon. Cubic boron nitride (cBN) is the second hardest of all known materials. The supply of such PcBN indexable inserts, which are only geometrically simple and available, requires several work procedures and is cost-intensive. The development of a cBN coating for cutting tools, combine the advantages of a thin film system and of cBN. Flexible cemented carbide tools, in respect to the geometry can be coated. The cBN films with a thickness of up to 2 μm on cemented carbide substrates show excellent mechanical and physical properties. This paper describes the results of the machining of various workpiece materials in turning and milling operations regarding the tool life, resultant cutting force components and workpiece surface roughness. In turning tests of Inconel 718 and milling tests of chrome steel the high potential of cBN coatings for dry machining was proven. The results of the experiments were compared with common used tool coatings for the hard machining. Additionally, the wear mechanisms adhesion, abrasion, surface fatigue and tribo-oxidation were researched in model wear experiments.

The relationships between ceramic tool life and different machining parameters

International Nuclear Information System (INIS)

El-Axir, M.H.; El-Masry, A.A.; Mashal, Y.A.H.

2001-01-01

With the increasing use of ceramic tool materials in applications, has come an increasing need for experimental data to assign the behavior of the life of these tool materials. Experimental results during turning operation show that it is possible to increase cutting tool life substantially by a proper variation of the cutting parameters used in this work. The tool lives (tool flank wear land length) of three different ceramic materials, namely; Silicon carbide (SiC), Alumina (Al/sub 2/O/sub 3/) and partially stabilized zirconia (PSZ) in addition to, Titanium carbide and high speed steel tools are investigated in this work. Also, The effect of varying the cutting speed, feed rate and tool rake angle on tool life of each tool material is studied. The experimental work was carried out utilizing one of the experimental design techniques based on response surface methodology. It was found that the SiC cutting tool showed the highest tool life among all materials tested in this work. It was also noticed that increasing the cutting speed has led to an increase in tool life for ceramic tools only. However, increasing the feed rate and tool rake angle resulted in a reduction in tool life in all materials examined in the present study. Further analysis conducted on SiC tool material to examine the effect of the interaction of cutting parameters on the tool life. (author)

Technology of high-speed combined machining with brush electrode

Science.gov (United States)

Kirillov, O. N.; Smolentsev, V. P.; Yukhnevich, S. S.

2018-03-01

The new method was proposed for high-precision dimensional machining with a brush electrode when the true position of bundles of metal wire is adjusted by means of creating controlled centrifugal forces appeared due to the increased frequency of rotation of a tool. There are the ultimate values of circumferential velocity at which the bundles are pressed against a machined area of a workpiece in a stable manner despite the profile of the machined surface and variable stock of the workpiece. The special aspects of design of processing procedures for finishing standard parts, including components of products with low rigidity, are disclosed. The methodology of calculation and selection of processing modes which allow one to produce high-precision details and to provide corresponding surface roughness required to perform finishing operations (including the preparation of a surface for metal deposition) is presented. The production experience concerned with the use of high-speed combined machining with an unshaped tool electrode in knowledge-intensive branches of the machine-building industry for different types of production is analyzed. It is shown that the implementation of high-speed dimensional machining with an unshaped brush electrode allows one to expand the field of use of the considered process due to the application of a multipurpose tool in the form of a metal brush, as well as to obtain stable results of finishing and to provide the opportunities for long-term operation of the equipment without its changeover and readjustment.

Microstructure evolution and mechanical properties of T15 high speed steel prepared by twin-atomiser spray forming and thermo-mechanical processing

International Nuclear Information System (INIS)

Zhang, Guoqing; Yuan, Hua; Jiao, Dongling; Li, Zhou; Zhang, Yong; Liu, Zhongwu

2012-01-01

Spray formed T15 high speed steel (HSS) billets were deposited using a state-of-the-art twin-atomiser spray forming facility. The effects of post thermo-mechanical processing (hot isostatic pressing and hot forging) and heat treatment on the microstructure and mechanical properties were investigated. As-deposited billet has a density over 99.3% of the theoretical value and no measurable macro-segregation was observed. The microstructure consists of the equiaxed grains with mean size of ∼18 μm and MC- and M 6 C-type carbides non-uniformly distributed inside the grains and along the grain boundaries. After optimal thermo-mechanical processing and heat treatment, the microstructure was composed of equiaxed fine tempered martensites, and refined M 6 C and MC spherical carbides particles uniformly distributed along the grain boundaries and inside the grains. The hardness reached HRC68 after thermo-mechanical processing, and the corresponding impact toughness and bending strength reached 27 J/cm 2 and 4600 MPa respectively. Although HIP cannot increase the bending strength significantly, it can effectively improve the impact toughness through refining and globurizing carbides.

The Mechanical and Tribology Properties of Sputtered Titanium Aluminum Nitride Coating on the Tungsten Carbide Insert Tool in the Dry Turning of Tool Steel

Directory of Open Access Journals (Sweden)

Esmar Budi

2015-02-01

Full Text Available The effect of the sputtering parameters on the mechanical tribology properties of Titanium Aluminum Nitride coating on the tungsten cabide insert tool in the dry turning of tool steel has been investigated. The coating was deposited using a Direct Current magnetron sputtering system with various substrate biases (-79 to -221 V and nitrogen flow rates (30 to 72 sccm. The dry turning test was carried out on a Computer Numeric Code machine using an optimum cutting parameter setting. The results show that the lowest flank wear (~0.4 mm was achieved using a Titanium Aluminum Nitride-coated tool that was deposited at a high substrate bias (-200 V and a high nitrogen flow rate (70 sccm. The lowest flank wear was attributed to high coating hardness.

Ultrahigh Ductility, High-Carbon Martensitic Steel

Science.gov (United States)

Qin, Shengwei; Liu, Yu; Hao, Qingguo; Zuo, Xunwei; Rong, Yonghua; Chen, Nailu

2016-10-01

Based on the proposed design idea of the anti-transformation-induced plasticity effect, both the additions of the Nb element and pretreatment of the normalization process as a novel quenching-partitioning-tempering (Q-P-T) were designed for Fe-0.63C-1.52Mn-1.49Si-0.62Cr-0.036Nb hot-rolled steel. This high-carbon Q-P-T martensitic steel exhibits a tensile strength of 1890 MPa and elongation of 29 pct accompanied by the excellent product of tensile and elongation of 55 GPa pct. The origin of ultrahigh ductility for high-carbon Q-P-T martensitic steel is revealed from two aspects: one is the softening of martensitic matrix due to both the depletion of carbon in the matensitic matrix during the Q-P-T process by partitioning of carbon from supersaturated martensite to retained austenite and the reduction of the dislocation density in a martensitic matrix by dislocation absorption by retained austenite effect during deformation, which significantly enhances the deformation ability of martensitic matrix; another is the high mechanical stability of considerable carbon-enriched retained austenite, which effectively reduces the formation of brittle twin-type martensite. This work verifies the correctness of the design idea of the anti-TRIP effect and makes the third-generation advanced high-strength steels extend to the field of high-carbon steels from low- and medium-carbon steels.

MATHEMATICAL FORMULATION OF PLASTIC CHARACTERISTICS OF WIRE OF STEEL 70 AT HIGH-SPEED WIRE DRAWING

Directory of Open Access Journals (Sweden)

Yu. L. Bobarikin

2011-01-01

Full Text Available The carried out numerical experiments subject to initial and boundary conditions indicate that mathematical model of elastic-plastic characteristics of steel 90 can be used for numerical calculations of wire drawing routes for this grade of steel.

Development Of A Dynamic Radiographic Capability Using High-Speed Video

Science.gov (United States)

Bryant, Lawrence E.

1985-02-01

High-speed video equipment can be used to optically image up to 2,000 full frames per second or 12,000 partial frames per second. X-ray image intensifiers have historically been used to image radiographic images at 30 frames per second. By combining these two types of equipment, it is possible to perform dynamic x-ray imaging of up to 2,000 full frames per second. The technique has been demonstrated using conventional, industrial x-ray sources such as 150 Kv and 300 Kv constant potential x-ray generators, 2.5 MeV Van de Graaffs, and linear accelerators. A crude form of this high-speed radiographic imaging has been shown to be possible with a cobalt 60 source. Use of a maximum aperture lens makes best use of the available light output from the image intensifier. The x-ray image intensifier input and output fluors decay rapidly enough to allow the high frame rate imaging. Data are presented on the maximum possible video frame rates versus x-ray penetration of various thicknesses of aluminum and steel. Photographs illustrate typical radiographic setups using the high speed imaging method. Video recordings show several demonstrations of this technique with the played-back x-ray images slowed down up to 100 times as compared to the actual event speed. Typical applications include boiling type action of liquids in metal containers, compressor operation with visualization of crankshaft, connecting rod and piston movement and thermal battery operation. An interesting aspect of this technique combines both the optical and x-ray capabilities to observe an object or event with both external and internal details with one camera in a visual mode and the other camera in an x-ray mode. This allows both kinds of video images to appear side by side in a synchronized presentation.

Development of a dynamic radiographic capability using high-speed video

International Nuclear Information System (INIS)

Bryant, L.E. Jr.

1984-01-01

High-speed video equipment can be used to optically image up to 2000 full frames per second or 12,000 partial frames per second. X-ray image intensifiers have historically been used to image radiographic images at 30 frames per second. By combining these two types of equipment, it is possible to perform dynamic x-ray imaging of up to 2,000 full frames per second. The technique has been demonstrated using conventional, industrial x-ray sources such as 150 kV and 300 kV constant potential x-ray generators, 2.5 MeV Van de Graaffs, and linear accelerators. A crude form of this high-speed radiographic imaging has been shown to be possible with a cobalt 60 source. Use of a maximum aperture lens makes best use of the available light output from the image intensifier. The x-ray image intensifier input and output fluors decay rapidly enough to allow the high frame rate imaging. Data are presented on the maximum possible video frame rates versus x-ray penetration of various thicknesses of aluminum and steel. Photographs illustrate typical radiographic setups using the high speed imaging method. Video recordings show several demonstrations of this technique with the played-back x-ray images slowed down up to 100 times as compared to the actual event speed. Typical applications include boiling type action of liquids in metal containers, compressor operation with visualization of crankshaft, connecting rod and piston movement and thermal battery operation. An interesting aspect of this technique combines both the optical and x-ray capabilities to observe an object or event with both external and internal details with one camera in a visual mode and the other camera in an x-ray mode. This allows both kinds of video images to appear side by side in a synchronized presentation

High-speed photography and holography of laser induced breakdown in liquids

International Nuclear Information System (INIS)

Lauterborn, W.

1979-01-01

Optical breakdown phenomena in liquids due to focused ruby laser light are investigated by high-speed photography and holography. Special attention is given the dynamics of the cavities produced in the liquid upon breakdown as they can be expected to become a powerful research tool in cavitation physics. To this end the production of three-dimensional breakdown configurations would be desirable as well as their investigation by high-speed holographic means. Both problems are presently under study. To achieve multiple breakdown at preselected points in the liquid a grating-lens assembly and digital holograms in photoresist are used. To film the motion of the cavities high-speed holocinematographic methods are developed. By now four to eight holograms can be taken at a rate of 10 to 20 kHz. (author)

Powering and Motion Predictions of High Speed Sea Lift (HSSL) Ships

National Research Council Canada - National Science Library

Gorski, Joseph; Miller, Ronald; Carrica, Pablo; Kandasamy, Mani; Stern, Fred

2007-01-01

High Speed Sea Lift (HSSL) is an important area of in terest for the US Navy. Computational tools are needed to predict the hydrodynamics of these configurations for their proper design and analysis in many areas including...

Design and application on experimental platform for high-speed bearing with grease lubrication

Directory of Open Access Journals (Sweden)

He Qiang

2015-12-01

Full Text Available The experimental platform for high-speed grease is an important tool for research and development of high-speed motorized spindle with grease lubrication. In this article, the experimental platform for high-speed grease is designed and manufactured which consists of the drive system, the test portion, the loading system, the lubrication system, the control system, and so on. In the meantime, the high-speed angular contact ceramic ball bearings B7005C/HQ1P4 as the research object are tested and contrasted in the grease lubrication and oil mist lubrication. The experimental platform performance is validated by contrast experiment, and the high-speed lubricated bearing performance is also studied especially in the relationship among the rotating speed,load and temperature rise. The results show that the experimental platform works steadily, accurate, and reliable in the experimental testing. And the grease lubrication ceramic ball bearings B7005C/HQ1P4 can be used in high-speed motorized spindle in the circular water cooling conditions when the rotating speed is lower than 40,000 r/min or the DN value (the value of the bearing diameter times the rotating speed is lower than the 1.44 × 106 mm r/min. Grease lubrication instead of oil mist lubrication under high-speed rotating will simplify the structure design of the high-speed motorized spindle and reduce the pollution to the environment.

Notch aspects of RSP steel microstructure

Directory of Open Access Journals (Sweden)

Michal Černý

2012-01-01

Full Text Available For a rather long time, basic research projects have been focused on examinations of mechanical properties for Rapid Solidification Powder (RSP steels. These state-of-art steels are commonly known as “powdered steels“. In fact, they combine distinctive attributes of conventional steel alloys with unusual resistance of construction material manufactured by so called “pseudo-powdered” metallurgy.Choice of suitable materials for experimental verification was carried out based on characteristic application of so called “modern steel”. First, groups of stainless and tool steel types (steel grades ČSN 17 and 19 were selected. These provided representative specimens for the actual comparison experiment. For stainless steel type, two steel types were chosen: hardenable X47Cr14 (ČSN 17 029 stainless steel and non-hardenable X2CrNiMo18-14-3 (ČSN 17 350 steel. They are suitable e.g. for surgical tools and replacements (respectively. For tooling materials, C80U (ČSN 19 152 carbon steel and American D2 highly-alloyed steel (ČSN “equivalent” being 19 572 steel were chosen for the project. Finally, the M390 Böhler steel was chosen as representative of powdered (atomized steels. The goal of this paper is to discuss structural aspects of modern stainless and tool steel types and to compare them against the steel made by the RSP method. Based on the paper's results, impact of powdered steel structural characteristics on the resistance to crack initiation shall be evaluated.

A low temperature aluminizing treatment of hot work tool steel

Energy Technology Data Exchange (ETDEWEB)

Matijevic, B., E-mail: bozidar.matijevic@fsb.hr [University of Zagreb, Faculty of Mechanical Engineering and Naval Architecture, Zagreb (Croatia)

2010-07-01

Conventional aluminizing processes by pack cementation are typically carried out at elevated temperatures. A low temperature powder aluminizing technology was applied to hot tool steel H13. The aluminizing treating temperature was from 550 to 620°C. Effects of temperature and time on the microstructure and phase evolution were investigated. Also, the intermetallic layer thickness was measured in the aluminized layer of a steel substrate. The cross-sectional microstructures, the aluminized layer thickness and the oxide layer were studied. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), glow discharge optical spectroscopy (GDOS) were applied to observe the cross-sections and the distribution of elements. (author)

A low temperature aluminizing treatment of hot work tool steel

International Nuclear Information System (INIS)

Matijevic, B.

2010-01-01

Conventional aluminizing processes by pack cementation are typically carried out at elevated temperatures. A low temperature powder aluminizing technology was applied to hot tool steel H13. The aluminizing treating temperature was from 550 to 620°C. Effects of temperature and time on the microstructure and phase evolution were investigated. Also, the intermetallic layer thickness was measured in the aluminized layer of a steel substrate. The cross-sectional microstructures, the aluminized layer thickness and the oxide layer were studied. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), glow discharge optical spectroscopy (GDOS) were applied to observe the cross-sections and the distribution of elements. (author)

Surface modification of AISI H13 tool steel by laser cladding with NiTi powder

Science.gov (United States)

Norhafzan, B.; Aqida, S. N.; Chikarakara, E.; Brabazon, D.

2016-04-01

This paper presents laser cladding of NiTi powder on AISI H13 tool steel surface for surface properties enhancement. The cladding process was conducted using Rofin DC-015 diffusion-cooled CO2 laser system with wavelength of 10.6 µm. NiTi powder was pre-placed on H13 tool steel surface. The laser beam was focused with a spot size of 90 µm on the sample surface. Laser parameters were set to 1515 and 1138 W peak power, 18 and 24 % duty cycle and 2300-3500 Hz laser pulse repetition frequency. Hardness properties of the modified layer were characterized by Wilson Hardness tester. Metallographic study and chemical composition were conducted using field emission scanning electron microscope and energy-dispersive X-ray spectrometer (EDXS) analysis. Results showed that hardness of NiTi clad layer increased three times that of the substrate material. The EDXS analysis detected NiTi phase presence in the modified layer up to 9.8 wt%. The metallographic study shows high metallurgical bonding between substrate and modified layer. These findings are significant to both increased hardness and erosion resistance of high-wear-resistant components and elongating their lifetime.

Influence of printing speed on production of embossing tools using FDM 3D printing technology

Directory of Open Access Journals (Sweden)

Jelena Žarko

2017-06-01

Full Text Available Manufacturing of the embossing tools customary implies use of metals such as zinc, magnesium, copper, and brass. In the case of short run lengths, a conventional manufacturing process and the material itself represent a significant cost, not only in the terms of material costs and the need for using complex technological systems which are necessary for their production, but also in the terms of the production time. Alternatively, 3D printing can be used for manufacturing similar embossing tools with major savings in production time and costs. However, due to properties of materials used in the 3D printing technology, expected results of embossing by 3D printed tools cannot be identical to metal ones. This problem is emphasized in the case of long run lengths and high accuracy requirement for embossed elements. The objective of this paper is primarily focused on investigating the influence of the printing speed on reproduction quality of the embossing tools printed with FDM (Fused Deposition Modelling technology. The obtained results confirmed that printing speed as a process parameter affects the reproduction quality of the embossing tools printed with FDM technology: in the case of deposition rate of 90 mm/s was noted the poorest dimensional accuracy in relation to the 3D model, which is more emphasised in case of circular and square elements. Elements printed with the highest printing speed have a greater dimensional accuracy, but with evident cracks on the surface.

Flank wear analysing of high speed end milling for hardened steel D2 using Taguchi Method

Science.gov (United States)

Hazza Faizi Al-Hazza, Muataz; Ibrahim, Nur Asmawiyah bt; Adesta, Erry T. Y.; Khan, Ahsan Ali; Abdullah Sidek, Atiah Bt.

2017-03-01

One of the main challenges for any manufacturer is how to decrease the machining cost without affecting the final quality of the product. One of the new advanced machining processes in industry is the high speed hard end milling process that merges three advanced machining processes: high speed milling, hard milling and dry milling. However, one of the most important challenges in this process is to control the flank wear rate. Therefore a analyzing the flank wear rate during machining should be investigated in order to determine the best cutting levels that will not affect the final quality of the product. In this research Taguchi method has been used to investigate the effect of cutting speed, feed rate and depth of cut and determine the best level s to minimize the flank wear rate up to total length of 0.3mm based on the ISO standard to maintain the finishing requirements.

Determining Ms temperature on a AISI D2 cold work tool steel using magnetic Barkhausen noise

Energy Technology Data Exchange (ETDEWEB)

Huallpa, Edgar Apaza, E-mail: gared1@gmail.com [Escola Politécnica da Universidade de São Paulo, Av. Prof. Mello Moraes 2463, 05508-030 SP (Brazil); Sánchez, J. Capó, E-mail: jcapo@usp.br [Departamento de Física, Facultad de Ciencias Naturales, Universidad de Oriente, Av. Patricio Lumumba s/n 90500, Santiago de Cuba (Cuba); Padovese, L.R., E-mail: lrpadove@usp.br [Escola Politécnica da Universidade de São Paulo, Av. Prof. Mello Moraes 2463, 05508-030 SP (Brazil); Goldenstein, Hélio, E-mail: hgoldens@usp.br [Escola Politécnica da Universidade de São Paulo, Av. Prof. Mello Moraes 2463, 05508-030 SP (Brazil)

2013-11-15

Highlights: ► MBN was used to follow the martensite transformation in a tool steel. ► The results were compared with resistivity experiments. ► The Ms was estimated with Andrews equation coupled to ThermoCalc calculations. The experimental results showed good agreement. -- Abstract: The use of Magnetic Barkhausen Noise (MBN) as a experimental method for measuring the martensite start (Ms) temperature was explored, using as model system a cold-work tool steel (AISI D2) austenitized at a very high temperature (1473 K), so as to transform in sub-zero temperatures. The progress of the transformation was also followed with electrical resistance measurements, optical microscopy and scanning electron microscopy. Both MBN and resistivity measurements showed a change near 230 K during cooling, corresponding to the Ms temperature, as compared with 245 K, estimated with Andrews empirical equation applied to the austenite composition calculated using ThermoCalc.

High speed digital holographic interferometry for hypersonic flow visualization

Science.gov (United States)

Hegde, G. M.; Jagdeesh, G.; Reddy, K. P. J.

2013-06-01

Optical imaging techniques have played a major role in understanding the flow dynamics of varieties of fluid flows, particularly in the study of hypersonic flows. Schlieren and shadowgraph techniques have been the flow diagnostic tools for the investigation of compressible flows since more than a century. However these techniques provide only the qualitative information about the flow field. Other optical techniques such as holographic interferometry and laser induced fluorescence (LIF) have been used extensively for extracting quantitative information about the high speed flows. In this paper we present the application of digital holographic interferometry (DHI) technique integrated with short duration hypersonic shock tunnel facility having 1 ms test time, for quantitative flow visualization. Dynamics of the flow fields in hypersonic/supersonic speeds around different test models is visualized with DHI using a high-speed digital camera (0.2 million fps). These visualization results are compared with schlieren visualization and CFD simulation results. Fringe analysis is carried out to estimate the density of the flow field.

Cathode-sputtered Ti-Zr-N-C-O base hard coatings and stability of said coatings on hard metals and working steels. Kathodenzerstaeubte Hartstoffschichten auf Basis Ti-Zr-N-C-O und deren Stabilitaet auf Hartmetall und Gebrauchsstaehlen

Energy Technology Data Exchange (ETDEWEB)

Boehmer, M.

1986-02-26

This paper deals with the examination of the metallurgical and thermal stability of the resistant material layers of titanium in connection with the substrate material influence. As substrate material were chosen: hard metal (81% WC, 12% TiC+TaC, 7% Co), high speed steel (DIN 1.3343), austenitic nickel chromium steel (X5 CrNi 18 9) and unalloyed tool steel (DIN 1.1545). The hard materials of titanium were deposited by means of cathode evaporation.

Temperature and emissivity determination of liquid steel S235

Science.gov (United States)

Schöpp, H.; Sperl, A.; Kozakov, R.; Gött, G.; Uhrlandt, D.; Wilhelm, G.

2012-06-01

Temperature determination of liquid metals is difficult but a necessary tool for improving materials and processes such as arc welding in the metal-working industry. A method to determine the surface temperature of the weld pool is described. A TIG welding process and absolute calibrated optical emission spectroscopy are used. This method is combined with high-speed photography. 2D temperature profiles are obtained. The emissivity of the radiating surface has an important influence on the temperature determination. A temperature dependent emissivity for liquid steel is given for the spectral region between 650 and 850 nm.

Temperature and emissivity determination of liquid steel S235

International Nuclear Information System (INIS)

Schöpp, H; Kozakov, R; Gött, G; Uhrlandt, D; Sperl, A; Wilhelm, G

2012-01-01

Temperature determination of liquid metals is difficult but a necessary tool for improving materials and processes such as arc welding in the metal-working industry. A method to determine the surface temperature of the weld pool is described. A TIG welding process and absolute calibrated optical emission spectroscopy are used. This method is combined with high-speed photography. 2D temperature profiles are obtained. The emissivity of the radiating surface has an important influence on the temperature determination. A temperature dependent emissivity for liquid steel is given for the spectral region between 650 and 850 nm. (paper)

Influence of hard particle addition and chemical interdiffusion on the properties of hot extruded tool steel compounds

International Nuclear Information System (INIS)

Silva, P.A.; Weber, S.; Inden, G.; Pyzalla, A.R.

2009-01-01

Low alloyed steel bars were co-extruded with pre-sintered tool steel powders with the addition of tungsten carbides (W 2 C/WC) as hard particles. During the hot extrusion process of these massive and powdery materials, an extrudate is formed consisting of a completely densified wear resistant coating layer and a bulk steel bar as the tough substrate core. This work combines experimental measurements (EPMA) and diffusion calculations (DICTRA TM ) to investigate the effect of hard particle addition and its dissolution, as well as the formation of M 6 C carbides on the properties of two different PM tool steel coatings hot extruded with a 1.2714 steel bar. A carburization effect resulting from the W 2 C hard particles is responsible for an increase of the 1.2344 steel matrix hardness. The mechanical properties of the interface region between coating matrix and substrate are influenced by chemical interdiffusion of carbon and other alloying elements occurring during heat treatment.

High-speed cinematography of gas-metal atomization

Energy Technology Data Exchange (ETDEWEB)

Ting, Jason [ALCOA Specialty Metals Division, 100 Technical Drive, Alcoa Center, PA 15069 (United States)]. E-mail: jason.ting@alcoa.com; Connor, Jeffery [Material Science Engineering Department, University of Pittsburgh, Pittsburgh, PA 15260 (United States); Ridder, Stephen [Metallurgical Processing Group, NIST, 100 Bureau Dr. Stop 8556, Gaithersburg, MD 20899 (United States)

2005-01-15

A high-speed cinematographic footage of a 304L stainless steel gas atomization, recorded at the National Institute of Standard and Technology (NIST), was analyzed using a discrete Fourier transform (DFT) algorithm. The analysis showed the gas atomization process possesses two prominent frequency ranges of melt oscillation (pulsation). A low-frequency oscillation in the melt flow occurring between 5.41 and 123 Hz, with a dominant frequency at 9.93 Hz, was seen in the recirculation zone adjacent to the melt orifice. A high-frequency melt oscillation range was observed above 123 Hz, and was more prominent one melt-tip-diameter downstream in the melt atomization image than upstream near the melt tip. This high-frequency range may reflect the melt atomization frequency used to produce finely atomized powder. This range also included a prominent high frequency at 1273 Hz, which dominated in the image further away downstream from the melt tip. This discrete high-frequency oscillation is most probably caused by the aeroacoustic ''screech'' phenomenon, intrasound (<20 kHz), a result of the atomizing gas jets undergoing flow resonance. It is hypothesized that this discrete intrinsic aeroacoustic tone may enhance melt breakup in the atomization process with evidence of this fact in the melt images.

High-speed cinematography of gas-metal atomization

International Nuclear Information System (INIS)

Ting, Jason; Connor, Jeffery; Ridder, Stephen

2005-01-01

A high-speed cinematographic footage of a 304L stainless steel gas atomization, recorded at the National Institute of Standard and Technology (NIST), was analyzed using a discrete Fourier transform (DFT) algorithm. The analysis showed the gas atomization process possesses two prominent frequency ranges of melt oscillation (pulsation). A low-frequency oscillation in the melt flow occurring between 5.41 and 123 Hz, with a dominant frequency at 9.93 Hz, was seen in the recirculation zone adjacent to the melt orifice. A high-frequency melt oscillation range was observed above 123 Hz, and was more prominent one melt-tip-diameter downstream in the melt atomization image than upstream near the melt tip. This high-frequency range may reflect the melt atomization frequency used to produce finely atomized powder. This range also included a prominent high frequency at 1273 Hz, which dominated in the image further away downstream from the melt tip. This discrete high-frequency oscillation is most probably caused by the aeroacoustic ''screech'' phenomenon, intrasound (<20 kHz), a result of the atomizing gas jets undergoing flow resonance. It is hypothesized that this discrete intrinsic aeroacoustic tone may enhance melt breakup in the atomization process with evidence of this fact in the melt images

Laser cutting of high manganese cast steel; Komangan chuko no laser setsudan

Energy Technology Data Exchange (ETDEWEB)

Kataoka, Y.; Tokunaga, T. [University of Industrial Technology, Kanagawa (Japan); Miyazaki, T. [Chiba Institute of Technology, Chiba (Japan)

1994-08-25

This paper discusses applicability of CO2 laser to cut high manganese cast steel, and investigates the cutting conditions and characteristics. The tested material is made of steel scrap, ferro Mn and ferro Cr of 50 kg in total, which was deoxidized by using pure aluminum and injected into CO2 die by means of the ordinary casting method to make a circular rod with a diameter of 28 mm. The rod was given a heating and water toughening treatment in a muffle furnace maintaining N2 atmosphere. The base structure is an austenite system of Mn 12.4% by mass with hardness of MHV 220 to 230. The paper describes discussions on test pieces (with a thickness of 2 mm) fabricated under a laser beam frequency of 150 Hz, power outputs of 250, 350 and 500 W, and cutting speeds of 100, 300 and 500 mm/min. The cutting width increases as the laser power is increased, but is not governed by the cutting speed. Increased cutting speed roughens the surface of a cut face. The laser cutting has caused no change in hardness of the base material, and no processing deterioration has been recognized. As described, the laser cutting can be applied to finish-cutting if the cutting condition is selected properly. Simplification of the cutting process and improvement of working environment can be expected from the laser cutting. 14 refs., 12 figs., 2 tabs.

Study of fish response using particle image velocimetry and high-speed, high-resolution imaging

Energy Technology Data Exchange (ETDEWEB)

Deng, Z. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Richmond, M. C. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Mueller, R. P. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Gruensch, G. R. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

2004-10-01

Fish swimming has fascinated both engineers and fish biologists for decades. Digital particle image velocimetry (DPIV) and high-speed, high-resolution digital imaging are recently developed analysis tools that can help engineers and biologists better understand how fish respond to turbulent environments. This report details studies to evaluate DPIV. The studies included a review of existing literature on DPIV, preliminary studies to test the feasibility of using DPIV conducted at our Flow Biology Laboratory in Richland, Washington September through December 2003, and applications of high-speed, high-resolution digital imaging with advanced motion analysis to investigations of fish injury mechanisms in turbulent shear flows and bead trajectories in laboratory physical models. Several conclusions were drawn based on these studies, which are summarized as recommendations for proposed research at the end of this report.

Method of treating tool steel die materials

International Nuclear Information System (INIS)

Cook, C.S.; Damon, S.

1981-01-01

In a method of hardening pilger dies to provide a hard case containing residual compressive stresses and tough body, the tool steel die is heated to the austenitizing temperature range, followed by selectively removing heat from the die at a predetermined faster rate in the direction of the desired case than the rate of heat removal from the balance of the die, and thereafter tempering the die. The invention provides a fully hardened and tempered case on the working surface of the die and a tough body in the balance of the die, usually of lower hardness. (author)

Thermally-Induced Crack Evaluation in H13 Tool Steel

Directory of Open Access Journals (Sweden)

Hassan Abdulrssoul Abdulhadi

2017-11-01

Full Text Available This study reported the effect of thermal wear on cylindrical tool steel (AISI H13 under aluminum die-casting conditions. The AISIH13 steels were immersed in the molten aluminum alloy at 700 °C before water-quenching at room temperature. The process involved an alternating heating and cooling of each sample for a period of 24 s. The design of the immersion test apparatus stylistically simulated aluminum alloy dies casting conditions. The testing phase was performed at 1850, 3000, and 5000 cycles. The samples were subjected to visual inspection after each phase of testing, before being examined for metallographic studies, surface crack measurement, and hardness characteristics. Furthermore, the samples were segmented and examined under optical and Scanning Electron Microscopy (SEM. The areas around the crack zones were additionally examined under Energy Dispersive X-ray Spectroscopy (EDXS. The crack’s maximum length and Vickers hardness profiles were obtained; and from the metallographic study, an increase in the number of cycles during the testing phase resulted in an increase in the surface crack formation; suggesting an increase in the thermal stress at higher cycle numbers. The crack length of Region I (spherically shaped was about 47 to 127 µm, with a high oxygen content that was analyzed within 140 µm from the surface of the sample. At 700 °C, there is a formation of aluminum oxides, which was in contact with the surface of the H13 sample. These stresses propagate the thermal wear crack length into the tool material of spherically shaped Region I and cylindrically shape Region II, while hardness parameters presented a different observation. The crack length of Region I was about 32% higher than the crack length of Region II.

COMPUTER MODELING IN DEFORM-3D FOR ANALYSIS OF PLASTIC FLOW IN HIGH-SPEED HOT EXTRUSION OF BIMETALLIC FORMATIVE PARTS OF DIE TOOLING

Directory of Open Access Journals (Sweden)

I. V. Kachanov

2015-01-01

Full Text Available The modern development of industrial production is closely connected with the use of science-based and high technologies to ensure competitiveness of the manufactured products on the world market. There is also much tension around an energy- and resource saving problem which can be solved while introducing new technological processes and  creation of new materials that provide productivity increase through automation and improvement of tool life. Development and implementation of such technologies are rather often considered as time-consuming processes  which are connected with complex calculations and experimental investigations. Implementation of a simulation modelling for materials processing using modern software products serves an alternative to experimental and theoretical methods of research.The aim of this paper is to compare experimental results while obtaining bimetallic samples of a forming tool through the method of speed hot extrusion and the results obtained with the help of computer simulation using DEFORM-3D package and a finite element method. Comparative analysis of plastic flow of real and model samples has shown that the obtained models provide high-quality and reliable picture of plastic flow during high-speed hot extrusion. Modeling in DEFORM-3D make it possible to eliminate complex calculations and significantly reduce a number of experimental studies while developing new technological processes.

Influence of cooling rate on phase formation in spray-formed H13 tool steel

Energy Technology Data Exchange (ETDEWEB)

McHugh, K.M. [Industrial Technology Department, Idaho National Laboratory, Idaho Falls, ID 83415-2050 (United States)], E-mail: kevin.mchugh@inl.gov; Lin, Y.; Zhou, Y.; Lavernia, E.J. [Department of Chemical Engineering and Materials Science, University of California, Davis, CA 95616 (United States)

2008-03-25

Spray forming is an effective way to process many tool steels into near-net-shape molds, dies, and related tooling. The general approach involves depositing atomized droplets onto a refractory pattern in order to image the pattern's features. The pattern is removed and the die insert is mounted in a standard mold base or holding block. This approach results in significant cost and lead-time savings compared to conventional machining. Spray-formed dies perform well in many industrial forming operations, oftentimes exhibiting extended die life compared to conventional dies of the same material and design. Care must be exercised when spray forming tool steel dies to minimize porosity and control the nature and distribution of phases and residual stresses. Selection of post-deposition heat treatment is important to tailor the die's properties (hardness, strength, impact energy, etc.) for a particular application. This paper examines how the cooling rate during spray processing and heat treatment of H13 tool steel influences phase formation. Porosity and hardness were evaluated over a range of deposit cooling rates and residual stresses were evaluated for a die in the as-deposited condition. Finally, the performance of spray-formed dies during production runs in forging, extrusion, and die casting is described.

Influence of cooling rate on phase formation in spray-formed H13 tool steel

International Nuclear Information System (INIS)

McHugh, K.M.; Lin, Y.; Zhou, Y.; Lavernia, E.J.

2008-01-01

Spray forming is an effective way to process many tool steels into near-net-shape molds, dies, and related tooling. The general approach involves depositing atomized droplets onto a refractory pattern in order to image the pattern's features. The pattern is removed and the die insert is mounted in a standard mold base or holding block. This approach results in significant cost and lead-time savings compared to conventional machining. Spray-formed dies perform well in many industrial forming operations, oftentimes exhibiting extended die life compared to conventional dies of the same material and design. Care must be exercised when spray forming tool steel dies to minimize porosity and control the nature and distribution of phases and residual stresses. Selection of post-deposition heat treatment is important to tailor the die's properties (hardness, strength, impact energy, etc.) for a particular application. This paper examines how the cooling rate during spray processing and heat treatment of H13 tool steel influences phase formation. Porosity and hardness were evaluated over a range of deposit cooling rates and residual stresses were evaluated for a die in the as-deposited condition. Finally, the performance of spray-formed dies during production runs in forging, extrusion, and die casting is described

A novel Mo-W interlayer approach for CVD diamond deposition on steel

Science.gov (United States)

Kundrát, Vojtěch; Zhang, Xiaoling; Cooke, Kevin; Sun, Hailin; Sullivan, John; Ye, Haitao

2015-04-01

Steel is the most widely used material in engineering for its cost/performance ratio and coatings are routinely applied on its surface to further improve its properties. Diamond coated steel parts are an option for many demanding industrial applications through prolonging the lifetime of steel parts, enhancement of tool performance as well as the reduction of wear rates. Direct deposition of diamond on steel using conventional chemical vapour deposition (CVD) processes is known to give poor results due to the preferential formation of amorphous carbon on iron, nickel and other elements as well as stresses induced from the significant difference in the thermal expansion coefficients of those materials. This article reports a novel approach of deposition of nanocrystalline diamond coatings on high-speed steel (M42) substrates using a multi-structured molybdenum (Mo) - tungsten (W) interlayer to form steel/Mo/Mo-W/W/diamond sandwich structures which overcome the adhesion problem related to direct magnetron sputtering deposition of pure tungsten. Surface, interface and tribology properties were evaluated to understand the role of such an interlayer structure. The multi-structured Mo-W interlayer has been proven to improve the adhesion between diamond films and steel substrates by acting as an effective diffusion barrier during the CVD diamond deposition.

A novel Mo-W interlayer approach for CVD diamond deposition on steel

Energy Technology Data Exchange (ETDEWEB)

Kundrát, Vojtěch; Sullivan, John; Ye, Haitao, E-mail: h.ye@aston.ac.uk [School of Engineering and Applied Science, Aston University, Birmingham, B4 7ET (United Kingdom); Zhang, Xiaoling; Cooke, Kevin; Sun, Hailin [Miba Coating Group: Teer Coatings Ltd, West-Stone-House, West-Stone, Berry-Hill-Industrial-Estate, WR9 9AS, Droitwich (United Kingdom)

2015-04-15

Steel is the most widely used material in engineering for its cost/performance ratio and coatings are routinely applied on its surface to further improve its properties. Diamond coated steel parts are an option for many demanding industrial applications through prolonging the lifetime of steel parts, enhancement of tool performance as well as the reduction of wear rates. Direct deposition of diamond on steel using conventional chemical vapour deposition (CVD) processes is known to give poor results due to the preferential formation of amorphous carbon on iron, nickel and other elements as well as stresses induced from the significant difference in the thermal expansion coefficients of those materials. This article reports a novel approach of deposition of nanocrystalline diamond coatings on high-speed steel (M42) substrates using a multi-structured molybdenum (Mo) – tungsten (W) interlayer to form steel/Mo/Mo-W/W/diamond sandwich structures which overcome the adhesion problem related to direct magnetron sputtering deposition of pure tungsten. Surface, interface and tribology properties were evaluated to understand the role of such an interlayer structure. The multi-structured Mo-W interlayer has been proven to improve the adhesion between diamond films and steel substrates by acting as an effective diffusion barrier during the CVD diamond deposition.

A novel Mo-W interlayer approach for CVD diamond deposition on steel

Directory of Open Access Journals (Sweden)

Vojtěch Kundrát

2015-04-01

Full Text Available Steel is the most widely used material in engineering for its cost/performance ratio and coatings are routinely applied on its surface to further improve its properties. Diamond coated steel parts are an option for many demanding industrial applications through prolonging the lifetime of steel parts, enhancement of tool performance as well as the reduction of wear rates. Direct deposition of diamond on steel using conventional chemical vapour deposition (CVD processes is known to give poor results due to the preferential formation of amorphous carbon on iron, nickel and other elements as well as stresses induced from the significant difference in the thermal expansion coefficients of those materials. This article reports a novel approach of deposition of nanocrystalline diamond coatings on high-speed steel (M42 substrates using a multi-structured molybdenum (Mo – tungsten (W interlayer to form steel/Mo/Mo-W/W/diamond sandwich structures which overcome the adhesion problem related to direct magnetron sputtering deposition of pure tungsten. Surface, interface and tribology properties were evaluated to understand the role of such an interlayer structure. The multi-structured Mo-W interlayer has been proven to improve the adhesion between diamond films and steel substrates by acting as an effective diffusion barrier during the CVD diamond deposition.

Hybrid Welding of 45 mm High Strength Steel Sections

Science.gov (United States)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F.

Thick section welding has significant importance for oil and gas industry in low temperature regions. Arc welding is usually employed providing suitable quality joints with acceptable toughness at low temperatures with very limited productivity compared to modern high power laser systems. Laser-arc hybrid welding (LAHW) can enhance the productivity by several times due to higher penetration depth from laser beam and combined advantages of both heat sources. LAHW was applied to join 45 mm high strength steel with double-sided technique and application of metal cored wire. The process was captured by high speed camera, allowing process observation in order to identify the relation of the process stability on weld imperfections and efficiency. Among the results, it was found that both arc power and presence of a gap increased penetration depth, and that higher welding speeds cause unstable processing and limits penetration depth. Over a wide range of heat inputs, the welds where found to consist of large amounts of fine-grained acicular ferrite in the upper 60-75% part of welds. At the root filler wire mixing was less and cooling faster, and thus found to have bainitic transformation. Toughness of deposited welds provided acceptable toughness at -50 °C with some scattering.

Research and Development of the Solidification of Slab Ingots from Special Tool Steels

Directory of Open Access Journals (Sweden)

Tkadlečková M.

2017-09-01

Full Text Available The paper describes the research and development of casting and solidification of slab ingots from special tool steels by means of numerical modelling using the finite element method. The pre-processing, processing and post-processing phases of numerical modelling are outlined. Also, problems with determining the thermophysical properties of materials and heat transfer between the individual parts of the casting system are discussed. Based on the type of grade of tool steel, the risk of final porosity is predicted. The results allowed to improve the production technology of slab ingots, and also to verify the ratio, the chamfer and the external/ internal shape of the wall of the new designed slab ingots.

Advanced high strength steels for automotive industry

Energy Technology Data Exchange (ETDEWEB)

Galan, J.; Samek, L.; Verleysen, P.; Verbeken, K.; Houbert, Y.

2012-11-01

The car industry is facing pressure because of the growing demand for more fuel-efficient passenger cars. In order to limit energy consumption and air pollution the weight of the car body has to be reduced. At the same time, high levels of safety have to be guaranteed. In this situation, the choice of material becomes a key decision in car design. As a response to the requirements of the automotive sector, high strength steels and advanced high strength steels have been developed by the steel industry. These modern steel grades offer an excellent balance of low cost, light weight and mechanical properties. (Author) 48 refs.

Analysis of carbides and inclusions in high speed tool steels

DEFF Research Database (Denmark)

Therkildsen, K.T.; Dahl, K.V.

2002-01-01

The fracture surfaces of fatigued specimens were investigated using scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). The aim was to quantify the distribution of cracked carbides and non-metallic inclusions on the fracturesurfaces as well as on polished cross...

Energetic optimization of regenerative braking for high speed railway systems

International Nuclear Information System (INIS)

Frilli, Amedeo; Meli, Enrico; Nocciolini, Daniele; Pugi, Luca; Rindi, Andrea

2016-01-01

Highlights: • A model of longitudinal dynamics of the High-speed train ETR1000 is presented. • The model includes on board traction and braking subsystems. • Interactions between overhead line and power line are modelled. • The model is validated on real experimental data. • An energy storage strategy for a high-speed line is proposed. - Abstract: The current development trend in the railway field has led to an ever increasing interest for the energetic optimization of railway systems (especially considering the braking phases), with a strong attention to the mutual interactions between the loads represented by railway vehicles and the electrical infrastructure, including all the sub-systems related to distribution and smart energy management such as energy storage systems. In this research work, the authors developed an innovative coupled modelling approach suitable for the analysis of the energetic optimization of railway systems and based on the use of the new object oriented language Matlab-Simscape™, which presents several advantages with respect to conventional modelling tools. The proposed model has been validated considering an Italian Direct Current High-speed line and the High-speed train ETR 1000. Furthermore, the model has been used to perform an efficiency analysis, considering the use of energy storage devices. The results obtained with the developed model show that the use of energy recovery systems in high-speed railway can provide great opportunities of energy savings.

An ultra-high speed whole slide image viewing system.

Science.gov (United States)

Yagi, Yukako; Yoshioka, Shigeatsu; Kyusojin, Hiroshi; Onozato, Maristela; Mizutani, Yoichi; Osato, Kiyoshi; Yada, Hiroaki; Mark, Eugene J; Frosch, Matthew P; Louis, David N

2012-01-01

One of the goals for a Whole Slide Imaging (WSI) system is implementation in the clinical practice of pathology. One of the unresolved problems in accomplishing this goal is the speed of the entire process, i.e., from viewing the slides through making the final diagnosis. Most users are not satisfied with the correct viewing speeds of available systems. We have evaluated a new WSI viewing station and tool that focuses on speed. A prototype WSI viewer based on PlayStation®3 with wireless controllers was evaluated at the Department of Pathology at MGH for the following reasons: 1. For the simulation of signing-out cases; 2. Enabling discussion at a consensus conference; and 3. Use at slide seminars during a Continuing Medical Education course. Pathologists were being able to use the system comfortably after 0-15 min training. There were no complaints regarding speed. Most pathologists were satisfied with the functionality, usability and speed of the system. The most difficult situation was simulating diagnostic sign-out. The preliminary results of adapting the Sony PlayStation®3 (PS3®) as an ultra-high speed WSI viewing system were promising. The achieved speed is consistent with what would be needed to use WSI in daily practice.

Microstructural investigations of interfaces in PVD TiN coated tool steels

NARCIS (Netherlands)

Carvalho, NJM; in't Veld, AJH; De Hosson, JTM; Lejcek, P; Paidar,

1999-01-01

The microstructure of PVD TiN coated tools steels composites has been investigated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). It was found that the microstructure of the coatings consists of a dense fibrous structure typical of a zone T structure. When the

The Effect of the Wear of Rotor Pins on Grinding Efficiency in a High-speed Disintegrator

Directory of Open Access Journals (Sweden)

Karel DVOŘÁK

2018-02-01

Full Text Available One of the directions intensively investigated in the field of milling is high-energy milling (HEM. One type of HEM is high-speed grinding in high-speed disintegrators. This type of mill is particularly suitable for the grinding and activation of fine powder materials. It has several advantages, such as a very intensive and continual refining process. One disadvantage is that its grinding pins are prone to abrasion, which may result in a decrease of the efficiency of grinding. This effect was investigated in this paper. Laboratory high speed disintegrator DESI 11 with steel pins was used. Portland clinker was chosen for the experiment, because of its average hardness. After each kilogram of the milled material, a sample was taken and the weight loss of the rotors was measured. The wear of the rotors was also measured using the 3D optical scanner ATOS Triple Scan. Results show that wear of rotors has a significant impact on the grinding efficiency.DOI: http://dx.doi.org/10.5755/j01.ms.24.1.17737

High Speed Blanking: An Experimental Method to Measure Induced Cutting Forces

OpenAIRE

GAUDILLIERE , Camille; Ranc , Nicolas; LARUE , Arnaud; MAILLARD , A; Lorong , Philippe

2013-01-01

Lien vers la version éditeur: http://link.springer.com/article/10.1007/s11340-013-9738-1; International audience; A new blanking process that involves punch speed up to 10 ms −1 has obvious advantages in increased productivity. However, the inherent dynamics of such a process makes it difficult to develop a practical high speed punch press. The fracture phenomenon governing the blanking process has to be well understood to correctly design the machine support and the tooling. To observe this ...

CrN-based wear resistant hard coatings for machining and forming tools

Energy Technology Data Exchange (ETDEWEB)

Yang, S; Cooke, K E; Teer, D G [Teer Coatings Ltd, West Stone House, Berry Hill Industrial Estate, Droitwich, Worcestershire WR9 9AS (United Kingdom); Li, X [School of Metallurgy and Materials, University of Birmingham, Birmingham B15 2TT (United Kingdom); McIntosh, F [Rolls-Royce plc, Inchinnan, Renfrewshire PA4 9AF, Scotland (United Kingdom)

2009-05-21

Highly wear resistant multicomponent or multilayer hard coatings, based on CrN but incorporating other metals, have been developed using closed field unbalanced magnetron sputter ion plating technology. They are exploited in coated machining and forming tools cutting and forming of a wide range of materials in various application environments. These coatings are characterized by desirable properties including good adhesion, high hardness, high toughness, high wear resistance, high thermal stability and high machining capability for steel. The coatings appear to show almost universal working characteristics under operating conditions of low and high temperature, low and high machining speed, machining of ordinary materials and difficult to machine materials, and machining under lubricated and under minimum lubricant quantity or even dry conditions. These coatings can be used for cutting and for forming tools, for conventional (macro-) machining tools as well as for micromachining tools, either as a single coating or in combination with an advanced, self-lubricating topcoat.

High Resolution Mapping of Wind Speed Using Active Distributed Temperature Sensing

Science.gov (United States)

Sayde, C.; Thomas, C. K.; Wagner, J.; Selker, J. S.

2013-12-01

We present a novel approach to continuously measure wind speed simultaneously at thousands of locations using actively heated fiber optics with a distributed temperature sensing system (DTS). Analogous to a hot-wire anemometer, this approach is based on the principal of velocity-dependent heat transfer from a heated surface: The temperature difference between the heated surface and ambient air is a function of the convective cooling of the air flowing past the surface. By knowing the thermal properties of the heated surface, the heating input, and ambient temperature, wind speed can be calculated. In our case, the heated surface consists of a thin stainless steel tube that can exceed several km in length. A fiber optic is enclosed within the stainless steel tube to report the heated tube temperature, which in this case was sampled every 0.125 m. Ambient temperature were measured by an independent fiber optic cable located proximally to the stainless steel tube. We will present the theoretical bases of measuring wind speed using heated fiber optic as well as validation of this method in the field. In the field testing, more than 5000 simultaneous wind speed measurements were obtained every 5.5 second at 3 elevations (2m, 1m, and 0.5 m) every 0.125 m along a 230 m transects located across a shallow gulley in Nunn, CO. This method, which provides both air temperature and wind speed spanning four orders of magnitude in spatial scale (0.1 - 1,000m) opens up many important opportunities for testing basic theories in micro-meteorology regarding spatial scales of turbulent length scales as a function of distance from the earth, development of internal boundary layers, applicability of Taylors hypothesis, etc. The equipment employed, including the heating system, which is available to all US scientists, was provided by CTEMPs.org thanks to the generous grant support from the National Science Foundation under Grant Number 1129003. Any opinions, findings, and conclusions or

An experimental investigation of pulsed laser-assisted machining of AISI 52100 steel

Science.gov (United States)

Panjehpour, Afshin; Soleymani Yazdi, Mohammad R.; Shoja-Razavi, Reza

2014-11-01

Grinding and hard turning are widely used for machining of hardened bearing steel parts. Laser-assisted machining (LAM) has emerged as an efficient alternative to grinding and hard turning for hardened steel parts. In most cases, continuous-wave lasers were used as a heat source to cause localized heating prior to material removal by a cutting tool. In this study, an experimental investigation of pulsed laser-assisted machining of AISI 52100 bearing steel was conducted. The effects of process parameters (i.e., laser mean power, pulse frequency, pulse energy, cutting speed and feed rate) on state variables (i.e., material removal temperature, specific cutting energy, surface roughness, microstructure, tool wear and chip formation) were investigated. At laser mean power of 425 W with frequency of 120 Hz and cutting speed of 70 m/min, the benefit of LAM was shown by 25% decrease in specific cutting energy and 18% improvement in surface roughness, as compared to those of the conventional machining. It was shown that at constant laser power, the increase of laser pulse energy causes the rapid increase in tool wear rate. Pulsed laser allowed efficient control of surface temperature and heat penetration in material removal region. Examination of the machined subsurface microstructure and microhardness profiles showed no change under LAM and conventional machining. Continuous chips with more uniform plastic deformation were produced in LAM.

Stahlschüssel key to steel

CERN Document Server

Wegst, W S

2016-01-01

The Key to Steel (Stahlschlüssel/Stahlschluessel) cross reference book will help you to decode / decipher steel designations and find equivalent materials worldwide. The 2016 edition includes more than 70,000 standard designations and trade names from approximately 300 steelmakers and suppliers. Presentation is trilingual: English, French, and German. Materials covered include structural steels, tool steels, valve steels, high temperature steels and alloys, stainless and heat-resisting steels, and more. Standards and designations from 25 countries are cross-referenced.

Acoustic Emission Methodology to Evaluate the Fracture Toughness in Heat Treated AISI D2 Tool Steel

Science.gov (United States)

Mostafavi, Sajad; Fotouhi, Mohamad; Motasemi, Abed; Ahmadi, Mehdi; Sindi, Cevat Teymuri

2012-10-01

In this article, fracture toughness behavior of tool steel was investigated using Acoustic Emission (AE) monitoring. Fracture toughness ( K IC) values of a specific tool steel was determined by applying various approaches based on conventional AE parameters, such as Acoustic Emission Cumulative Count (AECC), Acoustic Emission Energy Rate (AEER), and the combination of mechanical characteristics and AE information called sentry function. The critical fracture toughness values during crack propagation were achieved by means of relationship between the integral of the sentry function and cumulative fracture toughness (KICUM). Specimens were selected from AISI D2 cold-work tool steel and were heat treated at four different tempering conditions (300, 450, 525, and 575 °C). The results achieved through AE approaches were then compared with a methodology proposed by compact specimen testing according to ASTM standard E399. It was concluded that AE information was an efficient method to investigate fracture characteristics.

modelling of responses from orthogonal metal cutting of mild steel

African Journals Online (AJOL)

user

technical sciences which are shaped by local operating conditions. ... Three different tool types namely, HSS, tungsten carbide and carbide ... procedure indicated that a tape rule model Fat Max Blade. Armor 35' ... Carbon, C. 0.30 – 0.59% ... Block is Mild Steel x carbide. Runs. Cutting Speed. Feed Rate. Depth of Cut. 1. 250.

The structure and properties of ZrN-Ni-Co-coatings on the edges steel knives of wood-cutting tools

International Nuclear Information System (INIS)

Chaevskij, V.V.; Grishkevich, A.A.; Zhilinskij, V.V.; Kuleshov, A.K.

2015-01-01

Modes were selected and formed electroplated Ni-Co-coatings, ion-plasma Zr N-coatings as well as combined Zr N-Ni-Co-coating on the edges steel (type R6M5) knives of wood-cutting milling tools. Formed electroplated Ni-Co-layers are not mixed with the steel substrate and the Zr N-coating. Microhardness of combined Zr N-Ni-Co-coatings is to 1,2-1,5 times more than microhardness of steel base and bare steel. When cutting laminated chipboard by steel knives of milling tool with a Ni-Co- and Zr N-Ni-Co-coatings under laboratory conditions, abrasive surface wear type of edges knives is observed. Calculating bulk wear of edges knives with Zr N-Ni-Co-coatings showed reduction of more than 3 times value in comparison with knives with Ni-Co-coatings. Pilot testing of tool modified with combined Zr N-Ni-Co-coatings at OJSC 'Minskdrev' when cutting pine confirmed relevance of the tests carried out, as well as showed an increase in durability period of cutters to 30% compared with bare tool. (authors)

High-speed AC motors

Energy Technology Data Exchange (ETDEWEB)

Jokinen, T.; Arkkio, A. [Helsinki University of Technology Laboratory of Electromechanics, Otaniemi (Finland)

1997-12-31

The paper deals with various types of highspeed electric motors, and their limiting powers. Standard machines with laminated rotors can be utilised if the speed is moderate. The solid rotor construction makes it possible to reach higher power and speed levels than those of laminated rotors. The development work on high-speed motors done at Helsinki University of Technology is presented, too. (orig.) 12 refs.

Tooling solutions for sheet metal forming and punching of lean duplex stainless steel

DEFF Research Database (Denmark)

Wadman, Boel; Madsen, Erik; Bay, Niels

2012-01-01

.4509 and lean duplex EN1.4162 in a production designed for austenitic stainless steels, such as EN1.4301 and 1.4401. The result is a guideline that summarizes how stainless material properties may affect tool degradation, and suggests tool solutions for reduced production disturbances and tool maintenance cost.......For producers of advanced stainless components the choice of stainless material influences not only the product properties, but also the tooling solution for sheet metal stamping. This work describes how forming and punching tools will be affected when introducing the stainless alloys ferritic EN1...

Corrosion behavior of Al-Fe-sputtering-coated steel, high chromium steels, refractory metals and ceramics in high temperature Pb-Bi

International Nuclear Information System (INIS)

Abu Khalid, Rivai; Minoru, Takahashi

2007-01-01

Corrosion tests of Al-Fe-coated steel, high chromium steels, refractory metals and ceramics were carried out in high temperature Pb-Bi at 700 C degrees. Oxygen concentrations in this experiment were 6.8*10 -7 wt.% for Al-Fe-coated steels and 5*10 -6 wt.% for high chromium steels, refractory metals and ceramics. All specimens were immersed in molten Pb-Bi in a corrosion test pot for 1.000 hours. Coating was done with using the unbalanced magnetron sputtering (UBMS) technique to protect the steel from corrosion. Sputtering targets were Al and SUS-304. Al-Fe alloy was coated on STBA26 samples. The Al-Fe alloy-coated layer could be a good protection layer on the surface of steel. The whole of the Al-Fe-coated layer still remained on the base surface of specimen. No penetration of Pb-Bi into this layer and the matrix of the specimen. For high chromium steels i.e. SUS430 and Recloy10, the oxide layer formed in the early time could not prevent the penetration of Pb-Bi into the base of the steels. Refractory metals of tungsten (W) and molybdenum (Mo) had high corrosion resistance with no penetration of Pb-Bi into their matrix. Penetration of Pb-Bi into the matrix of niobium (Nb) was observed. Ceramic materials were SiC and Ti 3 SiC 2 . The ceramic materials of SiC and Ti 3 SiC 2 had high corrosion resistance with no penetration of Pb-Bi into their matrix. (authors)

Electromagnetic nondestructive evaluation of tempering process in AISI D2 tool steel

Science.gov (United States)

Kahrobaee, Saeed; Kashefi, Mehrdad

2015-05-01

The present paper investigates the potential of using eddy current technique as a reliable nondestructive tool to detect microstructural changes during the different stages of tempering treatment in AISI D2 tool steel. Five stages occur in tempering of the steel: precipitation of ɛ carbides, formation of cementite, retained austenite decomposition, secondary hardening effect and spheroidization of carbides. These stages were characterized by destructive methods, including dilatometry, differential scanning calorimetry, X-ray diffraction, scanning electron microscopic observations, and hardness measurements. The microstructural changes alter the electrical resistivity/magnetic saturation, which, in turn, influence the eddy current signals. Two EC parameters, induced voltage sensed by pickup coil and impedance point detected by excitation coil, were evaluated as a function of tempering temperature to characterize the microstructural features, nondestructively. The study revealed that a good correlation exists between the EC parameters and the microstructural changes.

Fast and accurate: high-speed metrological large-range AFM for surface and nanometrology

Science.gov (United States)

Dai, Gaoliang; Koenders, Ludger; Fluegge, Jens; Hemmleb, Matthias

2018-05-01

Low measurement speed remains a major shortcoming of the scanning probe microscopic technique. It not only leads to a low measurement throughput, but a significant measurement drift over the long measurement time needed (up to hours or even days). To overcome this challenge, PTB, the national metrology institute of Germany, has developed a high-speed metrological large-range atomic force microscope (HS Met. LR-AFM) capable of measuring speeds up to 1 mm s‑1. This paper has introduced the design concept in detail. After modelling scanning probe microscopic measurements, our results suggest that the signal spectrum of the surface to be measured is the spatial spectrum of the surface scaled by the scanning speed. The higher the scanning speed , the broader the spectrum to be measured. To realise an accurate HS Met. LR-AFM, our solution is to combine different stages/sensors synchronously in measurements, which provide a much larger spectrum area for high-speed measurement capability. Two application examples have been demonstrated. The first is a new concept called reference areal surface metrology. Using the developed HS Met. LR-AFM, surfaces are measured accurately and traceably at a speed of 500 µm s‑1 and the results are applied as a reference 3D data map of the surfaces. By correlating the reference 3D data sets and 3D data sets of tools under calibration, which are measured at the same surface, it has the potential to comprehensively characterise the tools, for instance, the spectrum properties of the tools. The investigation results of two commercial confocal microscopes are demonstrated, indicating very promising results. The second example is the calibration of a kind of 3D nano standard, which has spatially distributed landmarks, i.e. special unique features defined by 3D-coordinates. Experimental investigations confirmed that the calibration accuracy is maintained at a measurement speed of 100 µm s‑1, which improves the calibration efficiency by a

Comparative Investigation on Tool Wear during End Milling of AISI H13 Steel with Different Tool Path Strategies

Science.gov (United States)

Adesta, Erry Yulian T.; Riza, Muhammad; Avicena

2018-03-01

Tool wear prediction plays a significant role in machining industry for proper planning and control machining parameters and optimization of cutting conditions. This paper aims to investigate the effect of tool path strategies that are contour-in and zigzag tool path strategies applied on tool wear during pocket milling process. The experiments were carried out on CNC vertical machining centre by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. In an experiment with three factors at three levels, Response Surface Method (RSM) design of experiment with a standard called Central Composite Design (CCD) was employed. Results obtained indicate that tool wear increases significantly at higher range of feed per tooth compared to cutting speed and depth of cut. This result of this experimental work is then proven statistically by developing empirical model. The prediction model for the response variable of tool wear for contour-in strategy developed in this research shows a good agreement with experimental work.

Determination of tungsten in high-alloy steels and heat resisting alloys by isotope dilution-spark source mass spectrometry

International Nuclear Information System (INIS)

Saito, Morimasa; Yamada, Kei; Okochi, Haruno; Hirose, Fumio

1983-01-01

Tungsten in high-alloy steels and heat-resisting alloys was determined by isotope dilution method combined with spark source mass spectrometry by using 183 W enriched tungsten. The spike solution was prepared by fusing tungsten trioxide in sodium carbonate. A high-alloy steel sample was dissolved in the mixture of sulfuric acid and phosphoric acid together with the spike solution; a sample of heat resisting alloy was similarly dissolved in the mixture of hydrochloric acid, nitric acid, sulfuric acid, and phosphoric acid. The solution was evaporated to give dense white fumes. Tungsten was separated from the residue by a conventional cinchonine salt-precipitation method. The salt was ignited, and the residue was mixed with graphite powder and pressed into electrodes. The isotope 183 W and 184 W were measured. The method was applied to the determination of tungsten in JSS and NBS standard high-alloy steels and JAERI standard nickel- and NBS standard cobalt-base heat resisting alloys containing more than 0.05% tungsten. The results were obtained with satisfactory precision and accuracy. However, the results obtained for JSS standard high- speed steels containing molybdenum tended to be significantly lower than the certified values. (author)

Microstructure and Mechanical Properties of Thixowelded AISI D2 Tool Steel

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M. N. Mohammed

2018-05-01

Full Text Available Rigid perpetual joining of materials is one of the main demands in most of the manufacturing and assembling industries. AISI D2 cold work tool steels is commonly known as non-weldable metal that a high quality joint of this kind of material can be hardly achieved and almost impossible by conventional welding. In this study, a novel thixowelding technology was proposed for joining of AISI D2 tool steel. The effect of joining temperature, holding time and post-weld heat treatment on microstructural features and mechanical properties were also investigated. Acceptable joints without defect were achieved through the welding temperature of 1300 °C, while the welding at lower temperature resulted in a series of cracks across the entire joint that led to spontaneous fracture after joining. Tensile test results showed that maximum joint tensile strength of 271 MPa was achieved at 1300 °C and 10 min holding time, which was 35% of that of D2 base metal. Meanwhile, tensile strength of the joined parts after heat treatment showed a significant improvement over the non-heat treated condition with 560 MPa, i.e., about 70% of that of the strength value of the D2 base metal. This improvement in the tensile strength attributed to the dissolution of some amounts of eutectic chromium carbides and changes in the microstructure of the matrix. The joints are fractured at the diffusion zone, and the fracture exhibits a typical brittle characteristic. The present study successfully confirmed that by avoiding dendritic microstructure, as often resulted from the fusion welding, high joining quality components obtained in the semi-solid state. These results can be obtained without complex or additional apparatuses that are used in traditional joining process.

Implementation of straight and curved steel girder erection design tools construction : summary.

Science.gov (United States)

2010-11-05

Project 0-5574 Curved Plate Girder Design for Safe and Economical Construction, resulted in the : development of two design tools, UT Lift and UT Bridge. UT Lift is a spreadsheet-based program for analyzing : steel girders during lifting while ...

Modeling the influence of the parameters the diffusion of chromium plating on operational and physical and mechanical properties of steels for stamping tool

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Олександр Петрович Чейлях

2015-03-01

Full Text Available The diffusion hardening steel can be produced in any plant having a thermal equipment, besides, it is more economical than obtaining an alloy steel with similar properties. The influence of the parameters of the diffusion of chromium plating (the composition of the steel, powder mixture on the structure and mechanical properties of structural and tool steels was investigated. Results of X-ray analysis showed that the diffusion zone in the samples consists of two layers. First layer is predominantly carbides Cr7C3, Cr23C6, Fe3C. An intermediate layer composed of carbon-free solid solution of chromium in the iron. The maximum total thickness of the diffusion zone is observed in the steel 130Cr12V1 and 130Cr12Mo1 (~80 µm, minimum – in carbon steels 45, U10 (~10-30 µm. The thickness of carbide layer is approximately the same – 1-3 µm. Analyzing of data micro-hardness measurement across the thickness of the diffusion zone it must be noted that the diffusion layers of the samples of the tool steels have a high micro-hardness 6000-10000. The maximum HV=10200 was in steel 30Cr2W8V1. Chromium saturation of steel surface significantly increases its wear resistance. A much greater effect of increase of coefficient of relative wear resistance (3 fold increase was observed in steels 30Cr2W8V1, 130Cr12V1 and 130Cr12Mo1. The mathematical models relating the micro-hardness, wear resistance, the thickness of the diffusion layer were obtained. In view of the analytical relationships ascertained that the wear resistance of hardened steels substantially depend on the thickness of the diffusion coating, the micro-hardness of the layer and the core of steel and alloy steels has increased more than two times. For hardening steel punching tool 30Cr2W8V1 can be recommended composition of the powder mixture: 50% FeCr + 48% Al2O3 + 2% NaF, and for steel 130Cr12V1 preferably used as activator NH4F

Microanalysis of tool steel and glass with laser-induced breakdown spectroscopy

Science.gov (United States)

Loebe, Klaus; Uhl, Arnold; Lucht, Hartmut

2003-10-01

A laser microscope system for the microanalytical characterization of complex materials is described. The universal measuring principle of laser-induced breakdown spectroscopy (LIBS) in combination with echelle optics permits a fast simultaneous multielement analysis with a possible spatial resolution below 10 pm. The developed system features completely UV-transparent optics for the laser-microscope coupling and the emission beam path and enables parallel signal detection within the wavelength range of 200-800 nm with a spectral resolution of a few picometers. Investigations of glass defects and tool steels were performed. The characterization of a glass defect in a tumbler by a micro-LIBS line scan, with use of a 266-nm diode-pumped Nd:YAG laser for excitation, is possible by simple comparison of plasma spectra of the defect and the surrounding area. Variations in the main elemental composition as well as impurities by trace elements are detected at the same time. Through measurement of the calibration samples with the known concentration of the corresponding element, a correlation between the intensity of spectral lines and the element concentration was also achieved. The change of elemental composition at the transient stellite solder of tool steels has been determined by an area scan. The two-dimensional pictures show abrupt changes of the element distribution along the solder edge and allow fundamental researches of dynamic modifications (e.g., diffusion) in steel.

Performance evaluation of PCBN, coated carbide and mixed ceramic inserts in finish-turning of AISI D2 steel

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M. Junaid Mir

2017-09-01

Full Text Available The present study compares the performance of three different cutting tools, viz., PCBN, mixed ceramic and coated carbide tool in finish turning of hardened D2 tool steel in terms of tool wear, surface roughness, and economic feasibility under dry cutting conditions. Results showed that tool life of PCBN inserts was better than mixed ceramic and coated carbide inserts. The flank wear of PCBN tools was observed to be lower than mixed ceramic and coated carbide inserts. The surface roughness achieved under all cutting conditions for mixed ceramic and coated-carbide inserts was comparable with that achieved with PCBN inserts and was below 1.6μm. Experimental results showed that the wear mechanism of ceramic tool is pre-dominantly abrasive wear at lower speeds and abrasive wear followed by adhesive wear at medium and higher speeds and for PCBN tools the dominant wear mechanism is abrasive wear and cratering at lower speeds followed by adhesive wear at higher speeds. For carbide tool the dominant wear mechanism was abrasive wear and cratering at lower speeds followed by adhesion and chipping at higher speeds. Obtained results revealed that PCBN tools can outperform both ceramic and carbide tools in terms of tool life under different machinability criteria used.

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075.

Science.gov (United States)

Ghasemi, Amir Hossein; Khorasani, Amir Mahyar; Gibson, Ian

2018-01-16

Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5-8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.