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岡田, 将人 ; 細川, 晃 ; 浅川, 直紀 ; 藤田, 祐介 ; 上田, 隆司
概要:
The effect of minimum quantity lubrication (MQL) method in end milling of stainless steel and titanium alloy that are ty
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pical difficult-to-cut materials with coated carbide tool is investigated. The effect is mainly evaluated by tool flank temperature, cutting force and tool wear behavior. The tool flank temperature is measured using a two-color pyrometer with an optical fiber having small measurement area and high response speed under non-contact condition with tool. In MQL cutting of SUS304 and Ti-6A1-4V at cutting speed v=25m/min, the tool flank temperature decreases approximately 50°C and 100°C than the case of dry cutting respectively, and the effect of MQL on tool flank temperature is especially obtained in low-speed cutting. On the other hand, the tool flank temperature in MQL cutting of Ti-6A1-4V is higher than the case of dry cutting in cutting speed v=100m/min or more. In the high-speed cutting of Ti-6A1-4V, it is observed that the several chips adhere on the rake face of cutting edge. In addition, the output voltages from detector are obtained when the adhesion chips on the cutting edge pass through the measurement area of two-color pyrometer. In the case of the SUS304, the feed and thrust force are decreased by the supplying oil mist in high speed cutting. The generation of micro-crack at cutting edge is contained by applying MQL even high speed cutting of Ti-6A1-4V that is not obtained the effect of temperature decreasing. © 2012 The Japan Society of Mechanical Engineers.
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| 2.
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岡田, 将人 ; 上田, 隆司 ; 細川, 晃
概要:
The cutting performance of indexable insert drill that has non-axisymmetrical geometry is investigated. A solid drill th
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at has axisymmetrical and twisted geometry is also used to compare the cutting characteristics. The diameter of drills is 16mm and carbon steel is used as work material. The application effects of MQL that oil mist is supplied from oil holes in the tool are also examined. The temperature of peripheral corner edge of outer insert is measured using a two-color pyrometer with an optical fiber. The tool temperature of indexable insert drill is higher than that of solid drill and it reaches approximately 525°C at highest. On the other hand, the thrust force of indexable insert drill is lower than that of solid drill and it do not change so much with cutting speed. The surface roughness of indexable insert drill is approximately 1.15-5.4μm and this is higher than that of solid drill in each cutting speed. However, it is improved by supplying the oil mist.
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| 3.
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小矢, 畑亘 ; 岡田, 将人 ; 安井, 慎之介 ; 細川, 晃 ; 田中, 隆太郎 ; 上田, 隆司
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岡田, 将人 ; 上田, 隆司 ; 細川, 晃 ; 田中, 隆太郎
概要:
The cutting performance of indexable insert drill that has non-axisymmetrical geometry for drilling of difficult-to-cut
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materials is investigated. A twisted drill is also used to compare the cutting performance. The cutting characteristics are evaluated by tool flank temperature at peripheral corner edge θα, thrust force Ft, chip geometry and surface roughness Ra. The temperature of cutting tool is measured using a two-color pyrometer with an optical fiber. As work materials, the carbon steel, stainless steel, titanium alloy and nickel-base alloy are used. The θα and Ft of indexable insert drill are lower than that of solid drill in cutting of titanium alloy and nickel-base alloy. In the case of titanium alloy, the Ft of indexable insert drill is only 40% in the case of solid drill. On the other hand, this tendency reversed for stainless steel, and θα and Ft of indexable insert drill become higher than that of solid drill. The chip geometry by indexable insert drill is divided into parts in fragments so that there is chip breaker on the rake face of insert while the chip geometry by solid drill is continuous and long. The difference of surface roughness by the indexable insert drill and solid drill is negligible in the cutting of difficult-to-cut materials.
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岡田, 将人 ; 細川, 晃 ; 田中, 隆太郎 ; 上田, 隆司
概要:
The cutting performance of some coated carbide tools in hardmilling of hardened steel is investigated. The cutting chara
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cteristics are mainly evaluated by tool wear and temperature at flank face for four types of coating films on two types of base materials. Cutting force and surface roughness are also examined. The temperature of cutting tool is measured using a two-color pyrometer with an optical fiber. The tool flank wear becomes large in the case of TiN and TiCN coated tools. The tool flank temperature increases with the increase of surface roughness of coated film, and reaches approximately 500°C for TiAlN/ AlCrN coated tool. On the other hand, the cutting forces do not change so much with surface roughness of coated film. In the case of P30-grade cemented carbide as base material, tool flank wear and flank temperature become large compared with K10- grade. The surface roughness of workpiece increases with the increase in tool flank temperature more than approximately 530°C.
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田中, 隆太郎 ; 山根, 八洲男 ; 岡田, 将人 ; 細川, 晃 ; 上田, 隆司
概要:
This paper deals with the machinability of BN added Steels in end milling. The cutting tests were carried out by end mil
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ling carbon steel JIS S45C, S55C and these BN added steels with carbide tool and TiAlN coated carbide tool. Tool wear, cutting temperature, and, surface roughness were measured and discussed. In end milling BN added steel with square end mill, the progress rate of flank wear width was decreased and fracture at corner was suppressed in comparison with that in machining standard steel. In case of ball end mill, flank wear in end milling BN added steels were smaller in comparison with standard steel. In case of S45C, boundary wear was observed, however it was not observed in end milling BN added steel. BN added showed almost the same surface roughness as standard steel. The temperature of flank wear part in turning work based S55C were 50 °C higher in comparison with S45C base work. The temperature of throw away end mill was higher 100°C in comparison with solid square end mill. There were not significant difference between the temperature in end milling standard steel and BN added steels.
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細川, 晃 ; 岡田, 将人 ; 北川, 修介 ; 田中, 隆太郎 ; 上田, 隆司
概要:
The cutting performance of cBN tools for high-speed end milling of hardened steel is investigated. The cutting character
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istics are evaluated by tool temperature at the flank face, cutting force, chip geometry and surface roughness at the change of cutting speed ν and workpiece hardness. The temperature of cutting tool is measured using a two-color pyrometer with an optical fiber. The tool flank temperature θα increases with the increase of cutting speed and workpiece hardness, and reaches approximately 850°C at ν=600 m/min and HRC60. In particular, the workpiece hardness has great influence on the tool flank temperature. On the other hand, the principal cutting forces does not change so much with workpiece hardness. Based on the chip geometry measured, the most likely explanation for these phenomena is that chip formation process changes with workpiece hardness. As the workpiece hardness increases, the cutting actions become stable so that the surface roughness decreases. In the case of the low cBN content tool, tool flank temperature increases by 20∼50°C or more than high content one, because of the low thermal conductivity.
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| 8.
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岡田, 将人 ; 上田, 隆司 ; 細川, 晃
概要:
炭素鋼の穴あけ加工に刃先交換式ドリルを用いた場合の切削特性について，一般的なソリッドドリルと比較して検討した．加えて，MQLによる切削特性への影響を比較した．刃先交換式ドリルはソリッドドリルに比べ，工具温度が高く，仕上げ面性状は劣るが，スラ
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スト力は低い．刃先交換式ドリルによる切りくずは，チップブレーカにより細分化され排出された．オイルミストを供給することで，ソリッドドリルの場合よりも工具温度の低減効果が得られた．
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