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Title:
Tool-wear Study in Valve Seat Boring and Plunge Cutting of Powder Metal Steel and Optimization for Maximum Tool-life
PI: I.S. Jawahir
Graduate Students: K. Joshi and A. Venkatachalam
Sponsor: Toyota Motor Manufacturing North America (TMMNA)
Abstract
This project focuses on the effects of tool edge geometry and cutting conditions in finish machining of powder metal steels with Polycrystalline Cubic Boron Nitride (PCBN) and Carbide tools using flood cooling. The two different operations considered in this project are plunge cutting followed by boring. The plunge cutting operation creates the two surfaces (top and bottom) whereas the boring operation generates the critical (middle) surface. The flank wear (VB) is found to be the dominant form of tool-wear and abrasion is observed to be the dominant form of tool-wear mechanism in this machining process. The cutting tools are considered to be worn if the width of the bored surface goes out of tolerance. The tool cutting edge geometry parameters considered are chamfer angle, edge radius and nose radius. The interrelationships between the cutting edge geometry parameters and wear are established experimentally, providing a framework for modeling and optimization. An optimization model has been developed to predict the optimal tool edge geometry and cutting conditions for reduced tool-wear/increased tool-life.
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