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Characterization of micro-textured cutting tool surfaces for machining applications

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TitleInfo
Title
Characterization of micro-textured cutting tool surfaces for machining applications
Name (type = personal)
NamePart (type = family)
Patel
NamePart (type = given)
Kaushalendra
NamePart (type = date)
1994-
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Kaushalendra Patel
Role
RoleTerm (authority = RULIB)
author
Name (type = personal)
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Ozel
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Tugrul
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Tugrul Ozel
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Advisory Committee
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chair
Name (type = personal)
NamePart (type = family)
Luxhoj
NamePart (type = given)
James T.
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James T. Luxhoj
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Advisory Committee
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RoleTerm (authority = RULIB)
internal member
Name (type = personal)
NamePart (type = family)
Jeong
NamePart (type = given)
Myong K.
DisplayForm
Myong K. Jeong
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
internal member
Name (type = corporate)
NamePart
Rutgers University
Role
RoleTerm (authority = RULIB)
degree grantor
Name (type = corporate)
NamePart
School of Graduate Studies
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school
TypeOfResource
Text
Genre (authority = marcgt)
theses
OriginInfo
DateCreated (encoding = w3cdtf); (qualifier = exact)
2019
DateOther (encoding = w3cdtf); (qualifier = exact); (type = degree)
2019-05
CopyrightDate (encoding = w3cdtf); (qualifier = exact)
2019
Language
LanguageTerm (authority = ISO 639-3:2007); (type = text)
English
Abstract (type = abstract)
For high productivity, sustainable cutting tools with longer tool life and higher durability, which can withstand high temperature and pressure rises during high cutting speeds, are required in difficult-to-cut machining operations in aerospace, automotive, naval, nuclear and other industries. Currently, cutting coolants and lubricants (lubricoolants) are widely used in industry for thermal and tribological management which provide negative impacts on sustainable environment. The use of lubricoolants has to be reduced or totally eliminated through dry machining, decreasing the environmental hazard and manufacturing cost for improved sustainability. Micro-textured cutting tools can play an important role to achieve this goal. There are several distinct advantages offered by micro-textures applied to cutting tool surfaces to reduce cutting forces, friction, wear and material adherence. However, it is not clear what the optimum pattern and dimensions of these micro-micro-textures should be to obtain minimum forces and wear when using textured cutting tool surfaces in machining processes.
The current work is aimed at investigating the effect of micro-textured insert designs on the cutting forces, but also the effect of micro-groove dimension on the tool wear with experiments. It was expected that the proposed cutting tool surfaces will improve the tribological performance at tool and workpiece interfaces and reduce cutting forces, stresses, and temperatures, and consequently lower usage of energy, coolants, and lubricants in machining of difficult-to-cut materials.
In this research, we investigated the effect of various micro-textured insert designs on the cutting forces and tool wear with experiments in machining titanium alloy Ti-6Al-4V and alloy steel 4340. It was found that micro-texture parameters affect cutting forces and tool wear. Cutting forces are measured by using force dynamometers and the surface topography of the micro-textured tool surfaces were inspected using optical microscopy and focus variation techniques. Micro-texture parameters, groove depth, width, and spacing, are found to be influential on the amount of material smearing into grooves and adhering on the tool surface while reducing thrust forces due to lower contact. Multi-objective optimization studies were conducted to find cutting conditions and micro-groove parameters in machining steel alloy 4340 that minimizes cutting forces and wear. Therefore, the micro-texture design on the tool surfaces can be optimized to obtain lowered cutting forces, improved tool wear, and minimal material adherence. Micro-textured cutting tool parameters as decision variables can be optimized using appropriate optimization strategy that can be obtained from the solution sets. These micro-textures will enable users to practice environmentally sustainable machining through a better application of modern methods such as minimum quantity lubrication, near- dry cutting, cryogenic machining, and solid lubricants.
Subject (authority = local)
Topic
Micro-texture
Subject (authority = RUETD)
Topic
Industrial and Systems Engineering
Subject (authority = LCSH)
Topic
Cutting tools
RelatedItem (type = host)
TitleInfo
Title
Rutgers University Electronic Theses and Dissertations
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ETD
Identifier
ETD_9686
PhysicalDescription
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application/pdf
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text/xml
Extent
1 online resource (xii, 58 pages) : illustrations
Note (type = degree)
M.S.
Note (type = bibliography)
Includes bibliographical references
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School of Graduate Studies Electronic Theses and Dissertations
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rucore10001600001
Location
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NjNbRU
Identifier (type = doi)
doi:10.7282/t3-qsjh-vm08
Genre (authority = ExL-Esploro)
ETD graduate
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Rights

RightsDeclaration (ID = rulibRdec0006)
The author owns the copyright to this work.
RightsHolder (type = personal)
Name
FamilyName
Patel
GivenName
Kaushalendra
Role
Copyright Holder
RightsEvent
Type
Permission or license
DateTime (encoding = w3cdtf); (qualifier = exact); (point = start)
2019-04-09 03:44:49
AssociatedEntity
Name
Kaushalendra Patel
Role
Copyright holder
Affiliation
Rutgers University. School of Graduate Studies
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Author Agreement License
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I hereby grant to the Rutgers University Libraries and to my school the non-exclusive right to archive, reproduce and distribute my thesis or dissertation, in whole or in part, and/or my abstract, in whole or in part, in and from an electronic format, subject to the release date subsequently stipulated in this submittal form and approved by my school. I represent and stipulate that the thesis or dissertation and its abstract are my original work, that they do not infringe or violate any rights of others, and that I make these grants as the sole owner of the rights to my thesis or dissertation and its abstract. I represent that I have obtained written permissions, when necessary, from the owner(s) of each third party copyrighted matter to be included in my thesis or dissertation and will supply copies of such upon request by my school. I acknowledge that RU ETD and my school will not distribute my thesis or dissertation or its abstract if, in their reasonable judgment, they believe all such rights have not been secured. I acknowledge that I retain ownership rights to the copyright of my work. I also retain the right to use all or part of this thesis or dissertation in future works, such as articles or books.
Copyright
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Copyright protected
Availability
Status
Open
Reason
Permission or license
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2019-04-22T18:21:30
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2019-04-22T18:21:30
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