Search results

THE aerospace industry probably presents more machining problems in general than any other single industry. There are more high precision components found in aircraft than in most engineered equipment and a greater use of difficult to work exotic materials.

The aim of this paper is to review the literature on the prediction of cutting tool life. Tool life is typically estimated by predicting the time to reach the threshold flank wear width. The cutting tool is a crucial component in any machining process, and its failure affects the manufacturing process adversely. The prediction of cutting tool life by considering several factors that affect tool life is crucial to managing quality, cost, availability and waste in machining processes.

This study has undertaken the critical analysis and summarisation of various techniques used in the literature for predicting the life or remaining useful life (RUL) of the cutting tool through monitoring the tool wear, primarily flank wear. The experimental setups that comprise diversified machining processes, including turning, milling, drilling, boring and slotting, are covered in this review.

Cutting tool life is a stochastic variable. Tool failure depends on various factors, including the type and material of the cutting tool, work material, cutting conditions and machine tool. Thus, the life of the cutting tool for a particular experimental setup must be modelled by considering the cutting parameters.

This submission discusses tool life prediction comprehensively, from monitoring tool wear, primarily flank wear, to modelling tool life, and this type of comprehensive review on cutting tool life prediction has not been reported in the literature till now. The future suggestions provided in this review are expected to provide avenues to solve the unexplored challenges in this field.

Machining operations on multilayer circuit boards play the two major roles of establishing the finished geometry of the board and leading to the interconnection of the various conductor layers and it is likely that for some considerable time carbide cutting tools will continue to be used in the machining process. Fundamental and detailed considerations of the parameters influencing machining are presented prior to analysing the two predominant areas of use. Mention is made of some advanced machining techniques, involving mechanical, chemical and laser methods.

The purpose of this paper is to outline and document the failure root cause of a carbide cutting tool during machining of a hardened tool steel under automatic machining conditions.

Optical metallography and SEM/energy dispersive spectroscopy analysis, together with optical profilometry were employed for failure investigation. The use of an alternative cutting tool and modification of machining conditions are proposed as a failure preventive action.

Severe abrasive wear and adhesion of machining chips are observed in the flank zone, causing blunting of the cutting edge. The revision of cutting conditions, together with the use CBN-based tool insert leads to an overall improvement of the stability of the process and tool lifetime.

This paper places emphasis on a failure analysis case history following a structured approach in industrial machining problem solving, highlighting suggestions for process improvement.

Drilling and routing are the only two conventional mechanical machining techniques used in the production of printed circuit boards. Unfortunately these operations are still often underestimated even though drilling, in particular, is just as important as the other processes involved in achieving the final quality of the finished board. The advantages and disadvantages of the various drilling techniques are discussed. This paper was originally presented at the First Printed Circuit World Convention held at the Cafe Royal, London in June, 1978.

Cemented carbides are probably the most successful composite materials ever produced. They are best known for their outstanding wear resistance but many of their unusual properties remain largely unexploited. The author, Research and Development manager of Sandvik Hard Materials Ltd, Coventry, outlines the distinctive characteristics of this range of materials and illustrates their advantages in a wide field of engineering applications.

This study aims to clarify the influence mechanism of surface texture (arrays of circular/square and concave/convex) on the frictional properties of WC-TiC/Co cemented carbide under a water-miscible cutting fluid (JAEGER SW-105, 5 per cent) environment.

Four types of textured cemented carbide surfaces (arrays of circular/square and concave/convex that have different textured densities and sizes) were fabricated using laser surface technology. Pin-on-disc tests between an AISI 304 stainless steel ball and WC-TiC/Co cemented carbide samples were carried out for a variety of normal loads (1, 3 and 5 N) under a water-miscible cutting fluid environment. The effects of textured type, density and size on the friction coefficient were obtained.

Compared to a smooth surface, some textured samples successfully resulted in a reduced friction coefficient. The friction coefficient of textured WC-TiC/Co cemented carbide samples depended greatly on the textured type, density and size. Given the increase in textured density (ranging from 10 to 30 per cent), the friction coefficient of the test samples first decreased and then increased for all normal loads (1, 3 and 5 N), and the minimum friction coefficient was obtained at the textured density of 20 per cent. The concave textured surface showed obvious advantages in friction coefficient reduction regardless of textured density, size and normal load compared with the convex textured surface. Finally, the correlation between textured diameter/length and Hertzian contact width was studied for various normal loads and texture sizes. A 2.6 ratio of textured diameter/length to Hertzian contact width is recommended under for lubricated sliding contact with the water-miscible cutting fluid.

The main contribution of this work is in providing a design reference and obtaining an essential understanding on the effect of surface texture (arrays of circular/square and concave/convex) on the friction of WC-TiC/Co cemented carbide under a water-miscible cutting fluid environment.

The grain size and grain distribution mode have a significant impact on the tribological properties of Babbitt alloy. The purpose of this paper is to study the effect of differentiated SnSb grain size distribution on the improvement of tribological properties of Babbitt alloy.

Babbitt (marked by babbitt-cr), with a differentiated SnSb grain size distribution, was fabricated using a selective zone laser surface treatment. Bare Babbitt with coarse SnSb grain was marked as babbitt-c, and Babbitt with refined SnSb grain was marked as babbitt-r. The microstructure, microhardness and wettability of specimens were tested. The tribological properties of babbitt-c, babbitt-r and babbitt-cr were evaluated under dry and lubricated conditions.

The microstructure transforms from single coarse SnSb grain distribution or single refined SnSb grain distribution to differentiated SnSb grain size distribution, as a result of selective zone laser surface treatment. Among three specimens of microhardness, babbitt-cr showed the highest microhardness. The lipophilicity property of babbitt-cr was better compared to babbitt-c. A mixture of coarse and refined grain is beneficial to improve the tribological properties of Babbitt alloy under dry condition. Furthermore, compared with babbitt-c, the wear resistance of babbitt-cr was enhanced under lubricated condition. However, the anti-wear property of babbitt-cr was not significantly improved relative to babbitt-r with an increase in the loads.

The study demonstrates that modulated different grain size alternating distribution modes can improve the tribological properties of Babbitt alloy.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-09-2022-0259/

This study aims to evaluate the effects of the downhole environment and auxiliary rubber bellows on the contact mechanical characteristics and sealing performance of rubber-bellows mechanical seals (RBMS) in electric submersible pumps (ESPs), considering the elastic support of the rubber bellows, multi-field coupling effect and actual operating conditions.

A thermal-fluid-solid multi-field coupling numerical model for RBMS in ESPs is developed using the finite element analysis and influence coefficient method. Based on the contact mechanical characteristics of RBMS, the interactions of multiple physical fields between the sealing rings and lubricating oil are accounted for to assess the liquid lubrication state and sealing performance of RBMS in ESPs.

The findings indicate the anti-leakage effects of rubber bellows, the transition of lubrication state of the sealing end face and the evolution law of sealing performance with environmental pressure, axial compression amount and contact widths of rubber bellows.

This study innovatively proposes a multi-field numerical research method to reveal the impact of the downhole environment and rubber bellows on RBMS in ESPs. These findings contribute to a more comprehensive understanding of the sealing mechanism of RBMS and optimize the sealing design for ESPs in high-pressure environments.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2024-0369/

This study aims to improve the lubrication performance of molybdenum disulfide powders at textured surface of cemented carbide materials, a squeeze motion of vibration assistance method was introduced and investigated.

Surface texture was fabricated on YT15 cemented carbide samples using a laser marking machine. After that, a tribological experiment was carried out on a self-built friction testing machine under different amplitude and frequency of squeeze motion conditions. Moreover, a simulation model was also established to verify the principle of squeeze motion on the lubrication performance improving of MoS₂ particles at textured interfaces.

Analysis results indicated that surface texture on test sample can increase the storage ability of solid lubrication particles, and the lubrication film at the contact interface is more easily formed due to the reciprocating action. Squeeze motion can improve the storage ability of it due to an intermittent contact, which provides an opportunity for MoS₂ particles infiltration, and then a more uniform distribution and load-bearing properties of force chain are also established and formed simultaneously. Thus, a better tribological performance at the contact interface is obtained.

The main contribution of this work is to provide a reference for the molybdenum disulfide powder lubrication with textured surface of cemented carbide materials.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0166/