Predictive Modeling of Flank Wear in Turning Under Flood Cooling

2006 ◽  
Vol 129 (3) ◽  
pp. 513-519 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Metal Cutting ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machining Process ◽  
Analytical Models ◽  
Dynamic Strain ◽  
Process Conditions ◽  
Force Analysis

The objective of this paper is to present physical and quantitative models for the rate of tool flank wear in turning under flood cooling conditions. The resulting models can serve as a basis to predict tool life and to plan for optimal machining process parameters. Analytical models including cutting force analysis, cutting temperature prediction, and tool wear mechanics are presented in order to achieve a thermo-mechanical understanding of the tool wear process. The cutting force analysis leverages upon Oxley’s model with modifications for lubricating and cooling effect of overhead fluid application. The cutting temperature was obtained by considering workpiece shear deformation, friction, and heat loss along with a moving or stationary heat source in the tool. The tool wear mechanics incorporate the considerations of abrasive, adhesion, and diffusion mechanisms as governed by contact stresses and temperatures. A model of built-up edge formation due to dynamic strain aging has been included to quantify its effects on the wear mechanisms. A set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the material-dependent coefficients in the models. Experimental cutting data were also used to validate the predictive models by comparing cutting forces, cutting temperatures, and tool lives under various process conditions. The results showed that the predicted tool lives were close to the experimental data when the built-up edge formation model appropriately captured this phenomenon in metal cutting.

Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

Research on Wear Mechanisms while Turning Titanium Alloy TC4

2010 ◽  
Vol 97-101 ◽  
pp. 1845-1848
Author(s):  
Dong Liu ◽  
Wu Yi Chen ◽  
Hong Hai Xu ◽  
Xue Ke Luo
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
High Chemical ◽  
Adhesion Wear ◽  
Wear Tool ◽  
High Chemical Activity

Titanium alloys are widely used in aerospace industry due to their excellent mechanical properties. Because of their low thermal conductivity, high chemical activity, large friction coefficient and so on, such problems occur during the cutting process as high cutting temperature, large specific cutting force and serious tool wear, leading to low machining efficiency. The cutting force, forms of tool wear; wear mechanics were experimentally studied and analyzed while machining titanium alloy TC4 using carbide tools YS8 and YG8. The experimental results indicated that the tool wear of YG8 influenced cutting force not very remarkable when flank wear smaller than 0.25mm. But when the flank wear was bigger than 0.25mm, the cutting force increased rapidly with the flank wear increased. And the tool wear influenced the cutting force dramatically. The forms of tool wear during machining TC4 using carbide tool were adhesion wear, tool chipping and. The desquamation and chipping of tool caused by adhesion wear were the main reason of the tool failure.

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

scholarly journals Multiobjective Optimization of Tool Geometric Parameters Using Genetic Algorithm

Complexity ◽  
2018 ◽  
Vol 2018 ◽  
pp. 1-14 ◽  
Author(s):  
Maohua Du ◽  
Zheng Cheng ◽  
Yanfei Zhang ◽  
Shensong Wang
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Design Theory ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Functional Relation ◽  
Rake Angle ◽  
Geometric Parameters

Tool geometric parameters have a huge impact on tool wear. Up to now, there are only a few researches on tool geometric parameters and optimization, and the single objective function of parameter optimization used by researchers during high-speed machining (HSM) mainly is the minimum cutting force. However, the elevated cutting temperature also greatly affects tool wear due to the numerous cutting heat generation. Thus, to reduce tool wear, it is the most fundamental approach to taking into account the comprehensive control of the cutting force and cutting temperature because they are the two most important physical quantities in metal cutting processes. This work proposes a new optimization idea of the cutting-tool’s multi geometric parameters (three main parameters: rake angle, clearance angle, and cutting edge radius) with two objective functions (the cutting force and the temperature). Based on the response surface method (RSM), we have established the modified functional relation models of the influence of tool geometric parameters on the cutting force and temperature according to the finite element simulation results in high-speed cutting of Ti6Al4V. Then the models are solved by using a genetic algorithm, and the optimal tool geometric parameters values that can concurrently control the two objectives in their minimum values are obtained. The advantages lie in the strategy of the separate models of the cutting force and cutting temperature owing to their different dimensions and the solution of the models through giving the cutting force and cutting temperature different weight coefficients. The optimal results are verified by experiments, which shows that the optimal tool geometric parameters are very effective and vital for ensuring both the cutting force and the cutting temperature not too high. This work is of great significance to the cutting tool design theory and its manufacturing for reducing tool wear.

A Comparative Study of I-kaz Based Signal Analysis Techniques: Application to Detect Tool Wear during Turning Process

2013 ◽  
Vol 66 (3) ◽  
Author(s):  
Muhammad Rizal ◽  
Jaharah A. Ghani ◽  
Mohd Zaki Nuawi ◽  
Mohamad Amir Shafiq r Mohd Tahir ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Multilevel Methods ◽  
Machining Process ◽  
Turning Process ◽  
Feed Force ◽  
Machined Parts ◽  
Force Signal ◽  
Analysis Of Results

Detection of tool wear during in-progress machining process is a significant requirement to assure the quality of machined parts that helps to improve the productivity. The cutting force is one of the signals in machining process that has been widely used for tool wear monitoring. In the present paper three derived I-kazTM based methods explained and compared for monitoring tool wear changes during turning process. The aim of this work is to study the performance of I-kazTM, I-kaz 2D and I-kaz Multilevel techniques to detect flank wear width using the cutting force signal. The experiments were carried out by turning hardened carbon steel, and cutting force signals were measured by two channels of strain gauges that were mounted on the surface of tool holder. The analysis of results using I-kaz 2D, I-kazTM and also I-kaz Multilevel methods, revealed that all methods can applied to determine tool wear progression during turning process and feed force signal change is very significant due to flank wear.

A Novel Approach to Determine the Cutting Temperature Under Consideration of the Tool Wear

2020 ◽  
Author(s):  
Thomas Bergs ◽  
Bingxiao Peng ◽  
Daniel Schraknepper ◽  
Thorsten Augspurger
Keyword(s):  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Surface ◽  
Metal Cutting ◽  
Flank Wear ◽  
Wear Behavior ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Novel Approach ◽  
Flank Surface

Abstract In metal cutting process, modeling and predicting the tool wear development has been researched for decades. Many efforts have been made to study the cutting temperature as an indicator for the tool wear behavior. However, the determination of the cutting temperature in the critical contact area in process is still a challenge. In order to build temperature-dependent tool wear models, the temperature distribution of the workpiece was captured in this paper by an infrared thermography in orthogonal cutting of Direct Aged Inconel 718 with cemented carbide cutting tool WC-15Co. Instead of studying the temperature in critical cutting zone directly, the workpiece temperature distribution around the flank wear surface was determined inversely with the analytical Jaeger-solution based on the experimental data. The determined maximum cutting temperature on the flank wear surface has been successfully verified by FEM chip formation simulations. By means of this inverse approach, the cutting temperature on the flank surface can be determined as a function of tool wear VB. The experimental results showed that the cutting temperature increased with the increase of the tool wear VB. By means of this method, the temperature on the flank wear surface can be used as an important physical indicator to model and predict the tool wear development in future work.

On-Line Tool Wear Estimation Using Force Measurement and a Nonlinear Observer

1992 ◽  
Vol 114 (4) ◽  
pp. 666-672 ◽  
Author(s):  
Jong-Jin Park ◽  
A. Galip Ulsoy
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Process Model ◽  
Metal Cutting ◽  
Flank Wear ◽  
Force Measurement ◽  
Nonlinear Observer ◽  
Model Parameters ◽  
Force Measurements ◽  
On Line

On-line tool wear monitoring in metal-cutting operations is essential for an on-line process optimization. In this paper, tool flank wear is estimated on-line by utilizing a nonlinear observer with the feedback of cutting force measurements. Based on a previously developed cutting process model for turning, a nonlinear observer is designed such that the estimated flank wear converges to the actual flank wear development in the presence of poor initial estimates. The stability analysis for the resulting observer error dynamic system is carried out using a physical limitation of the actual flank wear development and the Total Stability Theorem. The experimental results show that the proposed nonlinear observer estimates the flank wear quite well not only in the presence of poor initial estimates but also in the presence of unexpected fluctuations in the cutting force measurements. However, the method has drawbacks resulting from difficulties in obtaining accurate model parameters. An adaptive version of the presented nonlinear observer, periodically calibrated by off-line direct tool wear measurements using computer vision, is considered to be a promising strategy for industrial implementation.

Experiment Study of Oil-Air Lubrication on Cooling of Turning Tools

2011 ◽  
Vol 189-193 ◽  
pp. 3187-3190 ◽  
Author(s):  
Jin Li Wang ◽  
Lin Cai ◽  
Hong Tao Zheng
Keyword(s):  
Metal Cutting ◽  
Research Work ◽  
Cutting Temperature ◽  
Cost Savings ◽  
Machining Process ◽  
Dry Cutting ◽  
Air Lubrication ◽  
Temperature Contrast ◽  
Cooling Technology ◽  
Lubrication Conditions

When lubricants are used according to special requirements, it is possible to achieve considerable cost savings. Compared to conventional coolant cooling technology used in metal cutting, oil-air lubrication increases cooling performance, avoids environmental pollution, reduces running and maintenance costs. The cutting temperature contrast experimental research was based on close to practice 45# steel in dry cutting, wet cutting and oil-air lubrication conditions. The research work concentrated on the superiority of oil-air lubrication cooling and the influence of cutting amount on temperature. The experimental results show that oil-air lubrication is more effective in reducing the cutting temperature than wet cutting or dry cutting, this paper details the cutting temperature curves at several different tests provides a basis for industrial production, improves the level of machining process and the significance was being reported.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

Sign in / Sign up

Export Citation Format

Share Document