scholarly journals Varying CFRP workpiece temperature during slotting: Effects on surface metrics, cutting forces and chip geometry

Procedia CIRP ◽  
2019 ◽  
Vol 85 ◽  
pp. 37-42 ◽  
Author(s):  
Sam Ashworth ◽  
J. Patrick A. Fairclough ◽  
Adrian R C Sharman ◽  
James Meredith ◽  
Yoshihiro Takikawa ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Workpiece Temperature ◽  
Surface Metrics ◽  
Chip Geometry

A New Method for Determining the Chip Geometry in Milling

2006 ◽  
Vol 526 ◽  
pp. 7-12
Author(s):  
M. San Juan ◽  
Francisco Santos Martin ◽  
T. de la Fuente ◽  
S. Aranda
Keyword(s):  
Cutting Forces ◽  
3D Model ◽  
Cutting Process ◽  
New Method ◽  
Fem Simulations ◽  
New Development ◽  
Experimental Cutting ◽  
Chip Geometry

Frequently, to validate FEM simulations of the cutting process it is compared the predicted results with the experimental cutting forces. In addition, other parameters are measured and it is possible to predict the chip geometry in some particular conditions. This paper presents a new development of the photogrammetry and its applications in the study of the chip geometry. In the orthogonal milling case, it is possible to obtain a 3D model of the deformed chip employing photogrammetry digitization techniques.

Mechanistic models for prediction of cutting forces and power consumption considering chip geometry

2020 ◽  
pp. 095440892096760
Author(s):  
V Umasai Vara Prasad ◽  
K Venkata Rao ◽  
PBGSN Murthy
Keyword(s):  
Numerical Simulation ◽  
Power Consumption ◽  
Cutting Force ◽  
Rotational Speed ◽  
Cutting Forces ◽  
Mechanistic Models ◽  
Aisi D2 Steel ◽  
Aisi D2 ◽  
Chip Geometry ◽  
D2 Steel

A novel approach for modeling and simulation of cutting force and power consumption in relation to chip geometry has been proposed in end milling‌ of AISI D2 steel. It is carried out in two stages: experimental work and finite element method based numerical simulation. In the first stage, experiments are conducted on the AISI D2 steel at two levels of spindle rotational speed, axial depth of cuts and four levels of feed per tooth using 10 mm and 8 mm diameter mill cutters. Cutting forces and amplitude of cutter vibration are measured in X and Y directions. Mechanistic models in terms of chip geometry and cutting force coefficients are developed to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation. In the second stage, numerical simulation is carried out to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation and compared with estimated values of cutting forces and power consumption. The maximum error between the two approaches for the cutting forces in X and Y directions and power consumption is estimated as 10.80%, 8.33% and 7.70% respectively. At spindle rotational speed of 2000 rpm, 0.3 mm of axial depth of cut and 50 µm of feed per tooth, the cutting forces and cutting power consumption are found minimum.

Virtual Model of Gear Shaping—Part I: Kinematics, Cutter–Workpiece Engagement, and Cutting Forces

2018 ◽  
Vol 140 (7) ◽  
Author(s):  
Andrew Katz ◽  
Kaan Erkorkmaz ◽  
Fathy Ismail
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Spur Gear ◽  
Cutting Edge ◽  
Prediction Algorithm ◽  
Force Model ◽  
Time Step ◽  
Solid Modeler ◽  
Chip Geometry ◽  
Gear Shaping

Gear shaping is, currently, the most prominent method for machining internal gears, which are a major component in planetary gearboxes. However, there are few reported studies on the mechanics of the process. This paper presents a comprehensive model of gear shaping that includes the kinematics, cutter–workpiece engagement (CWE), and cutting forces. To predict the cutting forces, the CWE is calculated at discrete time steps using a tridexel discrete solid modeler. From the CWE in tridexel form, the two-dimensional (2D) chip geometry is reconstructed using Delaunay triangulation (DT) and alpha shape reconstruction. This in turn is used to determine the undeformed chip geometry along the cutting edge. The cutting edge is discretized into nodes with varying cutting force directions (tangential, feed, and radial), inclination angles, and rake angles. If engaged in the cut during a particular time-step, each node contributes an incremental force vector calculated with the oblique cutting force model. Using a three-axis dynamometer on a Liebherr LSE500 gear shaping machine tool, the cutting force prediction algorithm was experimentally verified on a variety of processes and gears, which included an internal spur gear, external spur gear, and external helical gear. The simulated and measured force profiles correlate closely with about 3–10% RMS error.

Experimental and Numerical Study of Cutting Forces and Temperature Fields when Dry Turning Aluminum Alloy

2009 ◽  
Vol 407-408 ◽  
pp. 465-468 ◽  
Author(s):  
Lin Feng
Keyword(s):  
Aluminum Alloy ◽  
Cutting Forces ◽  
Numerical Study ◽  
Large Strain ◽  
Element Model ◽  
Temperature Fields ◽  
Orthogonal Turning ◽  
Tool Cutting ◽  
Chip Geometry ◽  
Cutting Experiments

A Lagrange finite element model is presented that simulates cutting forces and temperature distributions when orthogonal turning aluminum alloy. The effect of the large strain, strain-rate and temperature associated with cutting on the material properties is taken into account. The model predicts chip geometry, stress, strain and temperature distribution in the workpiece, chip, and tool. Cutting experiments were performed to validate the model.

Mechanics of Orthogonal Machining: Predicting Chip Geometry and Cutting Forces from Work-Material Properties and Cutting Conditions

1969 ◽  
Vol 184 (1) ◽  
pp. 927-942 ◽  
Author(s):  
R. G. Fenton ◽  
P. L. B. Oxley
Keyword(s):  
Excellent Agreement ◽  
Material Properties ◽  
Cutting Forces ◽  
Contact Length ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Orthogonal Machining ◽  
Work Material ◽  
Wide Range ◽  
Chip Geometry

A recently developed theory of orthogonal machining is used to calculate chip geometry (including tool-chip contact length) and cutting forces for SAE 1112 steel over a wide range of cutting conditions. A comparison with experimental results shows excellent agreement for most of the cutting conditions considered.

Chip geometry and cutting forces in gear power skiving

CIRP Annals ◽  
2019 ◽  
Vol 68 (1) ◽  
pp. 109-112 ◽  
Author(s):  
Pierce McCloskey ◽  
Andrew Katz ◽  
Luke Berglind ◽  
Kaan Erkorkmaz ◽  
Erdem Ozturk ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Power Skiving ◽  
Chip Geometry
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