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Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.
Víctor Criado; Norberto Feito; José Luis Cantero Guisández; José Díaz-Álvarez. A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds. Materials 2019, 12, 4074 .
AMA StyleVíctor Criado, Norberto Feito, José Luis Cantero Guisández, José Díaz-Álvarez. A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds. Materials. 2019; 12 (24):4074.
Chicago/Turabian StyleVíctor Criado; Norberto Feito; José Luis Cantero Guisández; José Díaz-Álvarez. 2019. "A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds." Materials 12, no. 24: 4074.
Nickel-based superalloys exhibit an exceptional combination of corrosion resistance, enhanced mechanical properties at high temperatures, and thermal stability. The mechanical behavior of nickel-based superalloys depends on the grain size and the precipitation state after aging. Haynes 282 was developed in order to improve the creep behavior, formability, and strain-age cracking of the other commonly used nickel-based superalloys. Nevertheless, taking into account the interest of the industry in the machinability of Haynes 282 because of its great mechanical properties, which is not found in other superalloys like Inconel 718 or Waspaloy, more research on this alloy is necessary. Cutting tools suffer extreme thermomechanical loading because of the high pressure and temperature localized in the cutting zone. The consequence is material adhesion during machining and strong abrasion due to the hard carbides included in the material. The main recommendations for finishing turning in Haynes 282 include the use of carbide tools, low cutting speeds, low depth of pass, and the use of cutting fluids. However, because of the growing interest in sustainable processes and cost reduction, dry machining is considered to be one of the best techniques for material removal. During the machining of Haynes 282, at both the finishing and roughing turning, cemented carbide inserts are most commonly used and are recommended all over the industry. This paper deals with the machining of Haynes 282 by means of coated carbide tools cutting fluids (dry condition). Different cutting speeds and feeds were tested to quantify the cutting forces, quality of surface, wear progression, and end of tool life. Tool life values similar to those obtained with a lubricant under similar conditions in other studies have been obtained for the most favorable conditions in dry environments.
Antonio Díaz-Álvarez; José Díaz-Álvarez; José Luis Cantero; Henar Miguélez. Sustainable High-Speed Finishing Turning of Haynes 282 Using Carbide Tools in Dry Conditions. Metals 2019, 9, 989 .
AMA StyleAntonio Díaz-Álvarez, José Díaz-Álvarez, José Luis Cantero, Henar Miguélez. Sustainable High-Speed Finishing Turning of Haynes 282 Using Carbide Tools in Dry Conditions. Metals. 2019; 9 (9):989.
Chicago/Turabian StyleAntonio Díaz-Álvarez; José Díaz-Álvarez; José Luis Cantero; Henar Miguélez. 2019. "Sustainable High-Speed Finishing Turning of Haynes 282 Using Carbide Tools in Dry Conditions." Metals 9, no. 9: 989.
Hybrid stack drilling is a very common operation used in the assembly of high-added-value components, which combines the use of composite materials and metallic alloys. This process entails the complexity of machining very dissimilar materials, simultaneously, on account of the interactions that are produced between them, during machining. This study analyzed the influence of Minimum Quantity Lubrication (MQL) on the performance of diamond-coated carbide tools when drilling Ti/carbon fiber reinforced plastics (CFRP)/Ti stacks. The main wear mechanism observed was diamond-coating detachment, followed by fragile breaks in the main cutting-edge. The tests done with the lower lubrication levels have shown an important adhesion of titanium (mainly on the secondary cutting-edge) and a higher friction between the tool and the workpiece, producing higher temperatures on the cutting region and a thermal softening effect on the workpiece. These phenomena affect the evolution of cutting power consumption with tool wear in the titanium layer. Regarding the quality of the test specimen, no significant differences were observed between the lubrication levels tested.
J. Fernández-Pérez; J. L. Cantero; J. Díaz-Álvarez; M. H. Miguélez. Hybrid Composite-Metal Stack Drilling with Different Minimum Quantity Lubrication Levels. Materials 2019, 12, 448 .
AMA StyleJ. Fernández-Pérez, J. L. Cantero, J. Díaz-Álvarez, M. H. Miguélez. Hybrid Composite-Metal Stack Drilling with Different Minimum Quantity Lubrication Levels. Materials. 2019; 12 (3):448.
Chicago/Turabian StyleJ. Fernández-Pérez; J. L. Cantero; J. Díaz-Álvarez; M. H. Miguélez. 2019. "Hybrid Composite-Metal Stack Drilling with Different Minimum Quantity Lubrication Levels." Materials 12, no. 3: 448.
Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds.
José Díaz-Álvarez; Antonio Díaz-Álvarez; Henar Miguélez; José Luis Cantero. Finishing Turning of Ni Superalloy Haynes 282. Metals 2018, 8, 843 .
AMA StyleJosé Díaz-Álvarez, Antonio Díaz-Álvarez, Henar Miguélez, José Luis Cantero. Finishing Turning of Ni Superalloy Haynes 282. Metals. 2018; 8 (10):843.
Chicago/Turabian StyleJosé Díaz-Álvarez; Antonio Díaz-Álvarez; Henar Miguélez; José Luis Cantero. 2018. "Finishing Turning of Ni Superalloy Haynes 282." Metals 8, no. 10: 843.
Inconel 718 is a nickel-based superalloy widely used in the aerospace industry, nuclear plants and gas turbines due to the exceptional mechanical properties and resistance to corrosion at elevated temperature. For these reasons Inconel 718 have a low machinability due to the high temperatures that appear in the cutting area in addition to the wear caused in the tools as abrasion, chemical affinity, diffusion, flank and notch wear. Carbide and recently Polycrystalline Cubic Boron Nitride (PCBN), are the cutting tool materials used in finishing operations of nickel-based superalloys. This paper focuses on the comparative analysis of carbide and PCBN tools in finishing operations on Inconel 718 using cutting fluid at conventional pressure (7.5 bar). Experimental tests were performed at different cutting speeds, feed rate and depths of cut depending of the cutting tool. PCBN tools were used at speeds within the range of 250-300 m/min, feed between 0.1 and 0.15 mm/rev and depth of 0.15mm. Carbide tools are not used at such speeds because of their lower hardness at high temperature. Speeds five times lower than those were used for PCBN (50-70 m/min), the same feeds (between 0.1 and 0.15 mm/rev) and a depth of 0.25 mm were used. Tool life and machined surface has been analyzed with the aim of studying the viability of these tools in finishing conditions of Inconel 718. The results indicate that PCBN tools have a shorter life in minutes than carbide tools; however, the machined surface by cutting edge is larger at higher cutting speeds, so PCBN tools are an interesting alternative in this type of machining.
Víctor Criado; José Díaz-Álvarez; José Luis Cantero; María Henar Miguélez. Study of the performance of PCBN and carbide tools in finishing machining of Inconel 718 with cutting fluid at conventional pressures. Procedia CIRP 2018, 77, 634 -637.
AMA StyleVíctor Criado, José Díaz-Álvarez, José Luis Cantero, María Henar Miguélez. Study of the performance of PCBN and carbide tools in finishing machining of Inconel 718 with cutting fluid at conventional pressures. Procedia CIRP. 2018; 77 ():634-637.
Chicago/Turabian StyleVíctor Criado; José Díaz-Álvarez; José Luis Cantero; María Henar Miguélez. 2018. "Study of the performance of PCBN and carbide tools in finishing machining of Inconel 718 with cutting fluid at conventional pressures." Procedia CIRP 77, no. : 634-637.
Inconel 718 is a difficult-to-cut material due to its poor thermal conductivity, severe work hardening and high strength at high temperature. Machining of Inconel 718 with Polycrystalline Cubic Boron Nitride (PCBN) tools at high speed in finishing operations may lead to brittle fracture in the cutting tool because of the low toughness of PCBN inserts in comparison to other cutting materials. PCBN inserts shaped with large tip radius are commonly used to remove small values of depth of cut in order to counteract these aspects. When applying multipass turning strategies with this configuration, a significant peak may occur in the response of the machining forces at the end of the pass in the second and successive passes. This fact may also be present when turning inner profiles or into a shoulder. The increase of the undeformed chip cross section and the high specific cutting forces of Inconel 718 give rise to this peak of the machining forces. In this work, different tests involving multipass finishing turning in Inconel 718 have been carried out in order to study the magnitude of the peak forces for different cutting conditions. A PCBN tool at high cutting speed with coolant has been employed at different feed rates and depths of cut. On the other hand, an analytical study of the undeformed chip section at the end of each turning pass has been performed in order to determine its relation to the machining peak forces. The results have shown that these peaks in the machining forces are strongly related to the tool tip radius and the cutting parameters. The machining force at the end of a turning pass can increase significantly their values during a short interval. Consequently, this effect may influence tool wear progression leading to a premature breakage of the tool.
Diego Infante-Garcia; José Diaz-Álvarez; José-Luis Cantero; Ana Muñoz-Sánchez; Maria-Henar Miguélez. Influence of the undeformed chip cross section in finishing turning of Inconel 718 with PCBN tools. Procedia CIRP 2018, 77, 122 -125.
AMA StyleDiego Infante-Garcia, José Diaz-Álvarez, José-Luis Cantero, Ana Muñoz-Sánchez, Maria-Henar Miguélez. Influence of the undeformed chip cross section in finishing turning of Inconel 718 with PCBN tools. Procedia CIRP. 2018; 77 ():122-125.
Chicago/Turabian StyleDiego Infante-Garcia; José Diaz-Álvarez; José-Luis Cantero; Ana Muñoz-Sánchez; Maria-Henar Miguélez. 2018. "Influence of the undeformed chip cross section in finishing turning of Inconel 718 with PCBN tools." Procedia CIRP 77, no. : 122-125.
Inconel 718 is a Ni superalloy widely used in high responsibility components requiring excellent mechanical properties at high temperature and elevated corrosion resistance. Inconel 718 is a difficult to cut material due to the elevated temperature generated during cutting, its low thermal conductivity, and the strong abrasive tool wear during cutting process. Finishing operations should ensure surface integrity of the component commonly requiring the use of hard metal tools with sharp tool edges and moderate cutting speeds. Polycrystalline cubic boron nitride (PCBN) tools recently developed an enhanced toughness suitable for these final operations. This paper focuses on the study of PCBN tools performance in finishing turning of Inconel 718. Several inserts representative of different manufacturers were tested and compared to a reference carbide tool. The evolution of tool wear, surface roughness, and cutting forces was analyzed and discussed. PCBN tools demonstrated their suitability for finishing operations, presenting reasonable removal rates and surface quality.
José Díaz-Álvarez; Víctor Criado; Henar Miguélez; José Luis Cantero. PCBN Performance in High Speed Finishing Turning of Inconel 718. Metals 2018, 8, 582 .
AMA StyleJosé Díaz-Álvarez, Víctor Criado, Henar Miguélez, José Luis Cantero. PCBN Performance in High Speed Finishing Turning of Inconel 718. Metals. 2018; 8 (8):582.
Chicago/Turabian StyleJosé Díaz-Álvarez; Víctor Criado; Henar Miguélez; José Luis Cantero. 2018. "PCBN Performance in High Speed Finishing Turning of Inconel 718." Metals 8, no. 8: 582.
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.
José Luis Cantero; José Díaz-Álvarez; Diego Infante-Garcia; Marcos Rodríguez; Víctor Criado. High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions. Metals 2018, 8, 192 .
AMA StyleJosé Luis Cantero, José Díaz-Álvarez, Diego Infante-Garcia, Marcos Rodríguez, Víctor Criado. High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions. Metals. 2018; 8 (3):192.
Chicago/Turabian StyleJosé Luis Cantero; José Díaz-Álvarez; Diego Infante-Garcia; Marcos Rodríguez; Víctor Criado. 2018. "High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions." Metals 8, no. 3: 192.
Ni-based superalloys are extensively used in high-responsibility applications in components of aerospace engines and gas turbines with high temperature service lives. The wrought, γ’-strengthened superalloy Haynes 282 has been recently developed for applications similar to other common superalloys, such as Waspaloy or Inconel 718, with improved creep behavior, thermal stability, and fabrication ability. Despite the potential of Haynes 282, there are still important gaps in the knowledge of the mechanical behavior of this alloy. In fact, it was not possible to find information concerning the mechanical behavior of the alloy under impulsive loading. This paper focuses on the mechanical characterization of the Haynes 282 at strain rates ranging from 0.1 to 2800 s−1 and high temperatures ranging from 293 to 523 K using Hopkinson bar compression tests. The experimental results from the thermo-mechanical characterization allowed for calibration of the Johnson–Cook model widely used in modeling metallic alloy’s responses under dynamic loading. Moreover, the behavior of Haynes 282 was compared to that reported for Inconel 718, and the results were used to successfully model the orthogonal cutting of Haynes 282, being a typical case of dynamic loading requiring previous characterization of the alloy.
Marcos Rodríguez-Millán; José Díaz-Álvarez; Richard Bernier; José Luis Cantero; Alexis Rusinek; María Henar Miguelez. Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation. Metals 2017, 7, 561 .
AMA StyleMarcos Rodríguez-Millán, José Díaz-Álvarez, Richard Bernier, José Luis Cantero, Alexis Rusinek, María Henar Miguelez. Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation. Metals. 2017; 7 (12):561.
Chicago/Turabian StyleMarcos Rodríguez-Millán; José Díaz-Álvarez; Richard Bernier; José Luis Cantero; Alexis Rusinek; María Henar Miguelez. 2017. "Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation." Metals 7, no. 12: 561.
The main goal of this paper is to show the new learning methodologies in techniques of forming process modelling in the context of Master in Industrial Engineering. In this context, Computer integrated manufacturing (CIM) has been established as a valuable tool for manufacturing process. The methodology developed in this work combines the process design, the usefulness workpiece and the computer aided (CAM).
Norberto Feito; Antonio Diaz; José Luis Cantero; Marcos Rodríguez Millán; Jorge López-Puente. Implementation of a Numerical Model to Define a Bending Manufacturing Process. Materials Science Forum 2016, 853, 36 -41.
AMA StyleNorberto Feito, Antonio Diaz, José Luis Cantero, Marcos Rodríguez Millán, Jorge López-Puente. Implementation of a Numerical Model to Define a Bending Manufacturing Process. Materials Science Forum. 2016; 853 ():36-41.
Chicago/Turabian StyleNorberto Feito; Antonio Diaz; José Luis Cantero; Marcos Rodríguez Millán; Jorge López-Puente. 2016. "Implementation of a Numerical Model to Define a Bending Manufacturing Process." Materials Science Forum 853, no. : 36-41.
It has been developed a bidimensional finite element model, which considers the thermal analysis of the material during the dry drilling of Ti6Al4V. Thermal loads that affect material have been calculated based on three-dimensional numerical models and the evolution of the torque experimentally measured in dry drilling of Ti6Al4V. Results of the numerical model have been compared with temperature values reached in the material at 1 mm from drill wall that was obtained experimentally. The developed numerical model to determine the evolution of the temperature in the material obtained during the drilling process gives relevant information for the control of thermal damage due to machining.
Antonio Diaz; J.A. De-La-Cruz-Hernández; J.L. Cantero-Guisández. Numerical Modelling of the Thermal Effects on Material in Drilling Processes Ti6Al4V Alloy. Procedia Engineering 2015, 132, 427 -432.
AMA StyleAntonio Diaz, J.A. De-La-Cruz-Hernández, J.L. Cantero-Guisández. Numerical Modelling of the Thermal Effects on Material in Drilling Processes Ti6Al4V Alloy. Procedia Engineering. 2015; 132 ():427-432.
Chicago/Turabian StyleAntonio Diaz; J.A. De-La-Cruz-Hernández; J.L. Cantero-Guisández. 2015. "Numerical Modelling of the Thermal Effects on Material in Drilling Processes Ti6Al4V Alloy." Procedia Engineering 132, no. : 427-432.
This paper focuses on the effect of the drill geometry on the drilling of woven Carbon Fiber Reinforced Polymer composite (CFRPs). Although different geometrical effects can be considered in drilling CFRPs, the present work focuses on the influence of point angle and wear because they are the important factors influencing hole quality and machining forces. Surface quality was evaluated in terms of delamination and superficial defects. Three different point angles were tested representative of the geometries commonly used in the industry. Two wear modes were considered, being representative of the wear patterns commonly observed when drilling CFRPs: flank wear and honed cutting edge. It was found that the crossed influence of the point angle and wear were significant to the thrust force. Delamination at the hole entry and exit showed opposite trends with the change of geometry. Also, cutting parameters were checked showing the feed’s dominant influence on surface damage.
Norberto Feito; José Díaz-Álvarez; Antonio Díaz-Álvarez; José Luis Cantero; María Henar Miguélez. Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs. Materials 2014, 7, 4258 -4271.
AMA StyleNorberto Feito, José Díaz-Álvarez, Antonio Díaz-Álvarez, José Luis Cantero, María Henar Miguélez. Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs. Materials. 2014; 7 (6):4258-4271.
Chicago/Turabian StyleNorberto Feito; José Díaz-Álvarez; Antonio Díaz-Álvarez; José Luis Cantero; María Henar Miguélez. 2014. "Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs." Materials 7, no. 6: 4258-4271.
This work is focused on the combined study of the evolution of tool wear, quality of machined holes and surface integrity of work-piece, in the dry drilling of alloy Ti–6Al–4V. Tool wear was studied with optical microscope and SEM–EDS techniques. The quality of machined holes was estimated in terms of geometrical accuracy and burr formation. Surface integrity involves the study of surface roughness, metallurgical alterations and microhardness tests. The end of tool life was reached because of catastrophic failure of the drill, but no significant progressive wear in cutting zone was observed previously. High hole quality was observed even near tool catastrophic failure, evaluated from the point of view of dimensions, surface roughness and burr height. However, microhardness measurements and SEM–EDS analysis of work-piece showed important microstructural changes related with a loss of mechanical properties. Depending on the application of the machined component, the state of the work-piece could be more restrictive than the tool wear, and the end of tool life should be established from the point of view of controlled damage in a work-piece.
J.L. Cantero; M.M. Tardío; J.A. Canteli; M. Marcos; M.H. Miguélez. Dry drilling of alloy Ti–6Al–4V. International Journal of Machine Tools and Manufacture 2005, 45, 1246 -1255.
AMA StyleJ.L. Cantero, M.M. Tardío, J.A. Canteli, M. Marcos, M.H. Miguélez. Dry drilling of alloy Ti–6Al–4V. International Journal of Machine Tools and Manufacture. 2005; 45 (11):1246-1255.
Chicago/Turabian StyleJ.L. Cantero; M.M. Tardío; J.A. Canteli; M. Marcos; M.H. Miguélez. 2005. "Dry drilling of alloy Ti–6Al–4V." International Journal of Machine Tools and Manufacture 45, no. 11: 1246-1255.