EXPERIMENTAL AND COMPUTATIONAL STUDY ON THE INFLUENCE OF CUTTING SPEED AND FEED RATE ON THE EFFICIENCY OF TUNGSTEN CARBIDE-COATED INSERTS IN CNC MILLING OF EN24 STEEL

Abstract

ABSTRACT This study investigates the impact of cutting speed and feed rate on the efficiency of tungsten carbide-coated inserts in CNC milling of EN24 steel, combining experimental and computational approaches. EN24 steel, known for its high strength and toughness, presents significant challenges in machining, making the optimization of cutting parameters crucial for enhancing tool life and surface finish. The experimental phase involved CNC milling tests where cutting speed and feed rate were systematically varied to assess their effects on tool wear, surface roughness, and 1----------motcriol-rcmoval-rate.-Tungsten_c;H~hi!le.:.c.Q<~_t.e.d inserts were used due to their high hardness and resistance to wear. The results showed a strong correlation between increased cutting speeds and accelerated tool wear, while higher feed rates led to rougher surface finishes but improved material removal rates. Complementary computational simulations were conducted using Finite Element Analysis (FEA) to -Q) model the cutting process, predicting thermal effects and stress distribution on the inserts. The simulations corroborated the experimental findings, offering insights into the thermal and mechanical stresses contributing to tool degradation. This combined approach provides a comprehensive understanding of the optimal cutting parameters, balancing tool life, surface quality, and machining efficiency. The study concludes that optimizing cutting speed and feed rate is critical for maximizing the performance of tungsten carbide-coated inserts in the milling of EN24 steel, with potential implications for improving productivity and reducing operational costs in industrial applications.

Specification

Experimental and Computational Study on the Influence of Cutting Speed and
Feed Rate on the Efficiency of Tungsten Carbide-Coated Inserts in CNC Milling
of EN24 Steel
PREAMBLE TO THE DESCRPTION
THE FIELD OF INVENTION
This invention relates to the optimization of CNC milling processes using tungsten
carbide-coated inserts, focusing on the experimental and computational analysis of cutting
speed and feed rate parameters to enhance efficiency, surface finish, and tool life during
the machining of EN24 steel.
BACKGROUND OF THE INVENTION
Jn~thuealm of CNC milling, optimizing tool performance is crucial for enhancing
efficiency and reducing costs. Tungsten carbide-coated inserts have emerged as a popular
choice due to their superior hardness and wear resistance. However, the performance of
these inserts can be significantly influenced by cutting parameters such as cutting speed
and feed rate. EN24 steel, a high-strength alloy commonly used in aerospace and
automotive industries, presents particular challenges due to its toughness and propensity
for tool wear. Existing research provides limited insight into how varying cutting
conditions affect the efficiency of tungsten carbide-coated inserts specifically when
machining EN24 steel. This study aims to bridge this gap by conducting both
experimental and computational analyses to understand the relationship between cutting
speed, feed rate, and insert efficiency. The findings will contribute to optimizing
machining processes, improving tool lifespan, and enhancing overall productivity in highprecision
manufacturing applications.
SUMMARY OF THE INVENTION
This study explores how varying cutting speeds and feed rates impact the performance of
tungsten carbide-coated inserts in CNC milling of EN24 steel. Through experimental and
computational analysis, it identifies optimal conditions to enhance milling efficiency,
aiming to improve tool longevity and machining accuracy.
Feed Rate on the Efficiency of Tungsten Carbide-Coated Inserts in CNC Milling
of EN24 Steel
COMPLETE SPECIFICATION
Specifications
• Objective: Analyze and compare the effects of varying cutting speeds and
feed rates on the performance and efficiency of tungsten carbide-coated
inserts in CNC milling operations of EN24 steel.
• Experimental Design: Conduct a series of controlled milling experiments
using tungsten carbide-coated inserts on EN24 steel under different cutting
------------~pe~r.ls-~nJ:lJeed_t:at~s to measure tool wear, surface finish, and material
removal rate.
• Computational Analysis: Utilize computational models to simulate the
milling process, focusing on the influence of cutting parameters on tool
efficiency and performance. Incorporate finite element analysis or other
relevant simulation techniques to predict wear patterns and optimize cutting
conditions.
• Performance Metrics: Evaluate the efficiency of the inserts based on
parameters such as tool life, cutting force, surface integrity of the machined
EN24 steel, and overall cost-effectiveness of the machining process.
• Data Analysis: Compare experimental results with computational predictions
to validate models and understand the relationship between cutting speed,
feed rate, and insert performance. Use statistical methods to assess the
significance of the observed effects and derive optimized cutting parameters
for improved millil}g efficiency
Experimental and Computational Study on the Influence of Cutting Speed and
Feed Rate on the Efficiency of Tungsten Carbide-Coated Inserts in CNC Milling
of EN24 Steel
COMPLETE SPECIFICATION
Specifications
• Objective: Analyze and compare the effects of varying cutting speeds and
feed rates on the performance and efficiency of tungsten carbide-coated
inserts in CNC milling operations of EN24 steel.
• Experimental Design: Conduct a series of controlled milling experiments
using tungsten carbide-coated inserts on EN24 steel under different cutting
------------~pe~r.ls-~nJ:lJeed_t:at~s to measure tool wear, surface finish, and material
removal rate.
• Computational Analysis: Utilize computational models to simulate the
milling process, focusing on the influence of cutting parameters on tool
efficiency and performance. Incorporate finite element analysis or other
relevant simulation techniques to predict wear patterns and optimize cutting
conditions.
• Performance Metrics: Evaluate the efficiency of the inserts based on
parameters such as tool life, cutting force, surface integrity of the machined
EN24 steel, and overall cost-effectiveness of the machining process.
• Data Analysis: Compare experimental results with computational predictions
to validate models and understand the relationship between cutting speed,
feed rate, and insert performance. Use statistical methods to assess the
significance of the observed effects and derive optimized cutting parameters
for improved millig efficiency.{
Experimental and Computational Study on the Influence of Cutting Speed and
Feed Rate on the Efficiency of Tungsten Carbide-Coated Insert~ in CNC Milling
of EN24 Steel
DESCRIPTION I
This study investigates the impact of cutting speed and feed rate on the performance of tungsten
carbide-coated inserts in CNC milling of EN24 steel, combining both experimental and
computational approaches. Tungsten carbide-coated inserts are known for their durability and
efficiency in machining high-strength materials like EN24 steel, a common alloy used in demanding
applications. The research evaluates how variations in cutting speed and feed rate affect key
performance metrics such as tool life, surface finish, and material removal rate. Experimental trials
· are conducted to gather empirical data, while computational simulations provide insights into the
------underlying_mec,h~nil;rrL~_and_QP.timizc milling_parameters. The study aims to enhance machining
efficiency and tool longevity by identifying optimal conditions for using tungsten carbide-coated
inserts, thereby contributing to improved manufacturing processes and cost-effectiveness in
machining EN24 steel components.

CLAIM
We Claim
I. Claim: Evaluates the impact of varying cutting speeds and feed rates on the efficiency
of tungsten carbide-coated inserts during CNC milling of EN24 steel.
2. Claim: Assesses how different cutting speeds and feed rates affect the wear rate and
lifespan of tungsten carbide-coated inserts.
3. Claim: Investigates the correlation between cutting parameters and the quality of the
surface finish achieved in EN24 steel milling.
4. Claim: Examines the relationship between cutting conditions and the performance
metrics of tungsten carbide-coated inserts, including tool life and cutting forces.
5. Claim: Provides computational and experimental data to optimize cutting_ paramete.rs
for enhanced milling efficiency and reduced tool wear.

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