INFLUENCE OF MACHINING PARAMETERS AND TOOL GEOMETRY ON TOOL WEAR DURING COBALT CHROMIUM-MOLYBDENUM MICRO DRILLING

Authors

  • Mohd Affifudin Abdul Patar Faculty of Mechanical Engineering, University Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
  • Mohd Azlan Suhaimi Faculty of Mechanical Engineering, Universiti Teknologi Malaysia http://orcid.org/0000-0003-2115-2030
  • Safian Sharif Faculty of Mechanical Engineering, University Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
  • Amrifan S Mohruni Faculty of Mechanical Engineering, Universitas Sriwijaya, 30128, Kota Palembang, Sumatera Selatan, Indonesia
  • Muhammad Juzaili Hisam Faculty of Mechanical Engineering, University Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
  • Mohd Sallehuddin Shaharum Faculty of Mechanical Engineering, University Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia

DOI:

https://doi.org/10.11113/jurnalteknologi.v86.20842

Keywords:

Tool wear, Tool geometry, Cobalt Chromium Molybdenum, Micro drilling

Abstract

Cobalt chromium (CoCr) alloys find extensive use in medical applications due to their unique mechanical properties, such as high strength and low thermal conductivity. However, machining these alloys poses challenges as they are classified as hard-to-cut materials, leading to issues like short tool life, poor surface quality, and low productivity. Rapid tool wear is a significant problem when machining hard alloys, with cutting parameters, drill bit geometry, and types of cutting fluids being the main factors influencing tool wear. In this study, a series of experiments was conducted to investigate the influence of different cutting speeds and tool geometry on tool wear during micro drilling of CoCrMo. A flood cooling system was employed throughout the study, with a constant machining feed rate of 0.1 mm/rev. Three cutting tools with different point angles (118°, 130°, and 140°) and a diameter of 0.2 mm were utilized. The cutting speeds of 50 m/min, 65 m/min, and 80 m/min were varied. A total of 11 runs were performed, with each run consisting of drilling 30 holes. Forces, torques, and tool wear were measured after every subsequent 10 holes drilled. The results indicate that the combination of a 140° point angle and an 80 m/min cutting speed yielded the best performance, exhibiting the lowest force, torque, and tool wear values.. 

References

Aerospace Materials: Past, Present and Future. 2012. Introduction to Aerospace Materials. Elsevier. 15-38.

Agarwala, David Bourell, Joseph Beaman, Harris Marcus, M. et al. 1995. Introduction Direct Selective Laser Sintering of Metals. Rapid Prototyping Journal. 1: 26-36.

Akhavan Farid, A., Sharif, S. and Idris, M. H. 2011. Chip Morphology Study in High Speed Drilling of Al-Si Alloy. International Journal of Advanced Manufacturing Technology. 57(5-8): 555-564.

Benezech, L., Landon, Y., & Rubio, W. 2012. Study of Manufacturing Defects and Tool Geometry Optimisation for Multi-material Stack Drilling. Advanced Materials Research. 423: 1-11.

Perçin, M., Aslantas, K., Ucun, I., Kaynak, Y., & Çicek, A. 2016. Micro-drilling of Ti-6Al-4V Alloy: The Effects of Cooling/lubricating. Precision Engineering. 45: 450-462.

Zitoune, R., Krishnaraj, V., & Collombet, F. 2010. Study of Drilling of Composite Material and Aluminium Stack. Composite Structures. 92(5): 1246-1255.

Baron, S., Desmond, D. and Ahearne, E. 2019. The Fundamental Mechanisms of Wear of Cemented Carbide in Continuous Cutting of Medical Grade Cobalt Chromium Alloy (ASTM F75). Wear. 424-425: 89-96.

Breitling, D. et al. (no date) Drilling of Metals. Çakir Şencan, A., Duran, A. and Şeker, U. 2020 The Effect of Different Cooling Methods to Hole Quality and Tool Life in the Drilling of AA7075 and AA2024 Aluminum Alloys.

Dornfeld, D., Min, S. and Takeuchi, Y. 2006. Recent Advances in Mechanical Micromachining. CIRP Annals - Manufacturing Technology. 55(2): 745-768.

Hassan, M. H., Abdullah, J., Mahmud, A. S., & Supran, A. 2018. Effect of Drill Geometry and Drilling Parameters on the Formation of Adhesion Layer in Drilling Composite-metal Stack-up Material. Journal of Mechanical Engineering. 5(Special Issue 2): 90-98.

Widodo, Redzuan, N., & Kurniawan, D. 2015. Evaluation of Hole Quality on Microdrilling AISI304 Austenitic Stainless Steel. Procedia Manufacturing. 2(February): 465-469.

Harun, M. H. S., Ghazali, M. F. and Yusoff, A. R. 2017. Analysis of Triaxial Force and Vibration Sensors for Detection of Failure Criterion in Deep Twist Drilling Process. International Journal of Advanced Manufacturing Technology. 89(9-12): 3535-3545.

Hasan, M., Zhao, J. and Jiang, Z. 2017. A Review of Modern Advancements in Micro Drilling Techniques. Journal of Manufacturing Processes. Elsevier Ltd. 343-375.

Hegab, H. and Kishawy, H. 2018. Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication. Journal of Manufacturing and Materials Processing. 2(3): 50.

Hu, P. S. et al. 2014. Investigation of Wear and Corrosion of a High-carbon Stellite Alloy for Hip Implants. Journal of Materials Engineering and Performance. 23(4): 1223-1230.

High Precision Machining Tool (HPMT). General Catalogue E, Solid Carbide Tools.

Jain, A. and Bajpai, V. 2020. Introduction to High-speed Machining (HSM). High-Speed Machining. Elsevier. 1-25.

Keaveney, S. et al. 2015. An Assessment of Medical Grade Cobalt Chromium Alloy ASTM F1537 as a Difficult-to-Cut (DTC) Material an Assessment of Medical Grade Cobalt Chromium Alloy ASTM F1537 as a ‘Difficult-to-Cut (DTC)’ Material.

Khanafer, K. et al. 2020. Toward Sustainable Micro-drilling of Inconel 718 Superalloy using MQL-Nanofluid. International Journal of Advanced Manufacturing Technology. 107(7-8): 3459-3469.

Kishawy, H. A. et al. 2005. Effect of Coolant Strategy on Tool Performance, Chip Morphology and Surface Quality during High-speed Machining of A356 Aluminum Alloy. International Journal of Machine Tools and Manufacture. 45(2): 219-227.

Kiswanto, G., Zariatin, D. L. and Ko, T. J. 2014. The Effect of Spindle Speed, Feed-rate and Machining Time to the Surface Roughness and Burr Formation of Aluminum Alloy 1100 in Micro-milling Operation. Journal of Manufacturing Processes. 6(4): 435-450.

Jiaqiang Dang, Gongyu Liu, Yaofeng Chen, Qinglong An, Weiwei Ming & Ming Chen. 2019. Experimental investigation on machinability of DMLS Ti6Al4V under dry drilling process. Materials and Manufacturing Processes. 34(7): 749-758.

Jadhav, S. S., Kakde, A. S., Patil, N. G., & Sankpal, J. B. 2018. Effect of Cutting Parameters, Point Angle and Reinforcement Percentage on Surface Finish, in Drilling of AL6061/Al2O3p MMC. Procedia Manufacturing. 20: 2-11.

Schweiger, J. et al. 2020. Internal Porosities, Retentive Force, and Survival of Cobalt–chromium Alloy Clasps Fabricated by Selective Laser-sintering. Journal of Prosthodontic Research. 64(2): 210-216.

Vaicelyte, A. et al. 2020. Cobalt–chromium Dental Alloys: Metal Exposures, Toxicological Risks, CMR Classification, and EU Regulatory Framework. Crystals. 1–16.

Aamir, M., Tu, S., Giasin, K., & Tolouei-Rad, M. 2020. Multi-hole Simultaneous Drilling of Aluminium Alloy: A Preliminary Study and Evaluation against One-shot Drilling Process. Journal of Materials Research and Technology. 9(3): 3994-4006.

Barman, A., Adhikari, R., & Bolar, G. 2020. Evaluation of Conventional Drilling and Helical Milling for Processing of Holes in Titanium Alloy Ti6Al4V. Materials Today: Proceedings. 28: 2295-2300.

Bogajo, I. R., Tangpronprasert, P., Virulsri, C., Keeratihattayakorn, S., & Arrazola, P. J. 2020. A Novel Indirect Cryogenic Cooling System for Improving Surface Finish and Reducing Cutting Forces when Turning ASTM F-1537 Cobalt-chromium Alloys. International Journal of Advanced Manufacturing Technology. 111(7-8): 1971-1989.

Venkatesan, K., Nagendra, K. U., Anudeep, C. M., & Cotton, A. E. 2021. Experimental Investigation and Parametric Optimization on Hole Quality Assessment During Micro-drilling of Inconel 625 Superalloy. Arabian Journal for Science and Engineering. 46(3): 2283-2309.

Haja Syeddu Masooth, P., & Jayakumar, V. 2020. Experimental Investigation on Surface Finish of Drilled Hole by TiAlN, TiN, AlCrN coated HSS Drill under Dry Conditions. Materials Today: Proceedings. 22: 315-321.

Khanna, N., Zadafiya, K., Patel, T., Kaynak, Y., Rahman Rashid, R. A., & Vafadar, A. 2021. Review on Machining of Additively Manufactured Nickel and Titanium Alloys. Journal of Materials Research and Technology. 15: 3192-3221.

Suresh Kumar, B., Baskar, N., & Rajaguru, K. 2020. Drilling Operation: A Review. Materials Today: Proceedings. 21: 926-933.

Zhao, S. et al. 2003. Microstructural Stability and Mechanical Properties of a New Nickel-based Superalloy. Materials Science and Engineering A. 355(1-2): 96-105.

Downloads

Published

2024-01-15

Issue

Section

Science and Engineering

How to Cite

INFLUENCE OF MACHINING PARAMETERS AND TOOL GEOMETRY ON TOOL WEAR DURING COBALT CHROMIUM-MOLYBDENUM MICRO DRILLING. (2024). Jurnal Teknologi, 86(2), 101-114. https://doi.org/10.11113/jurnalteknologi.v86.20842