Mechanistic Force Models for Chip Control Tools

1999 ◽  
Vol 121 (3) ◽  
pp. 408-416 ◽  
Author(s):  
R. Zhu ◽  
S. G. Kapoor ◽  
R. E. DeVor ◽  
S. M. Athavale
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Mechanistic Modeling ◽  
Design Parameters ◽  
Tool Geometry ◽  
Workpiece Material ◽  
Machining Forces ◽  
Cutting Energy ◽  
Friction Energy ◽  
Good Agreement

A mechanistic modeling approach to predicting machining forces for grooved tools is developed. The models are based solely on the grooved tool geometry and the specific normal cutting energy and friction energy for flat tools. Special grooved tools (M2 grade HSS) were designed and fabricated and orthogonal cutting tests were performed to validate the model. The workpiece material used was Al 6061-T6. The force predictions from the model are found in good agreement with the measured forces. The effects of groove design parameters on the cutting forces are also determined.

Modeling of Forces for Drills With Chip-Breaking Grooves

2004 ◽  
Vol 126 (3) ◽  
pp. 555-564 ◽  
Author(s):  
Sushanta K. Sahu ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Low Carbon Steel ◽  
High Speed Steel ◽  
Mechanistic Modeling ◽  
Design Parameters ◽  
Low Carbon ◽  
Workpiece Material ◽  
Chip Breaking ◽  
Twist Drills

In this paper, a mechanistic modeling approach to predicting cutting forces for conical twist drills with chip-breaking grooves has been developed. The model is based on force principles for restricted contact cutting extended to take into account the presence of a groove on the drill rake face. The applicability of the model for arbitrary groove geometries has been ensured by eliminating the use of grooved drills in the calibration process. Four different combinations of groove geometries have been used for validating the model using high speed steel drills and low carbon steel workpiece material. The force predictions from the model were found to be in good agreement with the measured forces. The model was then employed to determine groove orientation and design parameters that minimize cutting forces, subject to the condition that chip breaking is satisfactory.

Prediction of Cutting Forces in Milling Stainless Steels using Chamfered Main Cutting Edge Tool

2005 ◽  
Vol 21 (3) ◽  
pp. 145-155 ◽  
Author(s):  
C.-S. Chang
Keyword(s):  
Stainless Steel ◽  
Cutting Forces ◽  
Steel Plate ◽  
Cutting Edge ◽  
304 Stainless Steel ◽  
Workpiece Material ◽  
Material Force ◽  
Force Data ◽  
Edge Tool ◽  
Good Agreement

AbstractTo study the cutting forces, the carbide tip's surface temperature, and the mechanism of secondary chip and main chip formation of face milling stainless steel with a chamfered main cutting edge has been investigated. Theoretical values of cutting forces were calculated and compared to the experimental results with SUS 304 stainless steel plate as a workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. A comparison of the predicted and measured forces shows good agreement. A preliminary discussion is also made for the design of special tool holders and their geometrical configurations. Next, the tips mounted in the tool holders are ground to a chamfered width and the tool dimensions are measured by using a toolmaker microscope.

Residual Stress Prediction by Means of 3D FEM Simulation

2011 ◽  
Vol 223 ◽  
pp. 431-438 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Cristian Cappellini ◽  
Claudio Giardini
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Stress Measurement ◽  
Numerical Models ◽  
Orthogonal Cutting ◽  
Residual Stress Distribution ◽  
Tool Geometry ◽  
Distribution Analysis ◽  
3D Fem ◽  
Workpiece Material

In cutting field, residual stress distribution analysis on the workpiece is a very interesting topic. Indeed, the residual stress distribution affects fatigue life, corrosion resistance and other functional aspects of the workpiece. Recent studies showed that the development of residual stresses is influenced by the cutting parameters, tool geometry and workpiece material. For reducing the costs of experimental tests and residual stress measurement, analytical and numerical models have been developed. The aim of these models is the possibility of forecasting the residual stress distribution into the workpiece as a function of the selected process parameters. In this work the residual stress distributions obtained simulating cutting operations using a 3D FEM software and the corresponding simulation procedure are reported. In particular, orthogonal cutting operations of AISI 1045 and AISI 316L steels were performed. The FEM results were compared with the experimental residual stress distribution in order to validate the model effectiveness.

scholarly journals Modeling and Control of Cutter Vibration in the Presence of Random Distribution of Microhardness of Workpiece and Nonlinear Cutting Forces in Lathe Process

2011 ◽  
Vol 2011 ◽  
pp. 1-11 ◽  
Author(s):  
A. H. El-Sinawi
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Random Distribution ◽  
Orthogonal Cutting ◽  
Nonlinear Dynamic Model ◽  
Linear Quadratic ◽  
Workpiece Material ◽  
Actuator Dynamics ◽  
Modeling And Control ◽  
And Control

This work presents a comprehensive approach to the control of tool's position, in the presence of machine tool structure vibration, nonlinear cutting force, and random tool vibration due to random distribution of microhardness of workpiece material. The controller is combination of Proportional and linear quadratic gaussian- (P-LQG-) type constructed from an augmented model of both tool-actuator dynamics and a nonlinear dynamic model relating tool displacement to cutting forces. The latter model is obtained using black-box system identification of experimental orthogonal cutting data in which tool displacement is the input and cutting force is the output. The controller is evaluated and its performance is demonstrated.

Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics

2000 ◽  
Vol 124 (1) ◽  
pp. 32-41 ◽  
Author(s):  
D. Arola ◽  
M. B. Sultan ◽  
M. Ramulu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Deformable Body ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Tool Geometry ◽  
Reinforced Plastics ◽  
Edge Trimming

A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.

scholarly journals A Slip-Line Field for Ploughing During Orthogonal Cutting

1998 ◽  
Vol 120 (4) ◽  
pp. 693-699 ◽  
Author(s):  
D. J. Waldorf ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Slip Line ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Great Promise ◽  
Uncut Chip Thickness ◽  
Workpiece Material ◽  
Line Field ◽  
Slip Line Field ◽  
Edge Radius

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and for negative rake angle orthogonal cutting. It incorporates the observed phenomena of a small stable build-up of material adhered to the edge and a raised prow of material formed ahead of the edge. The model shows how ploughing forces are related to cutter edge radius—a larger edge causing larger ploughing forces. A series of experiments were run on 6061-T6 aluminum using tools with different edge radii—including some exaggerated in size—and different levels of uncut chip thickness. Resulting force measurements match well to predictions using the proposed slip-line field. The results show great promise for understanding and quantifying the effects of edge radius and worn tool on cutting forces.

scholarly journals Force Prediction in Ultrasonic Vibration-Assisted Milling

2019 ◽  
Author(s):  
Yixuan Feng ◽  
Fu-Chuan Hsu ◽  
Yu-Ting Lu ◽  
Yu-Fu Lin ◽  
Chorng-Tyan Lin ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Tool Geometry ◽  
Force Model ◽  
Type I ◽  
Vibration Displacement ◽  
Milling Forces ◽  
Instantaneous Uncut Chip Thickness

Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

Finite Element Simulation of Cutting Forces in Orthogonal Machining of Titanium Alloy Ti-6Al-4V

2014 ◽  
Vol 474 ◽  
pp. 192-199 ◽  
Author(s):  
Ladislav Kandráč ◽  
Ildikó Maňková ◽  
Marek Vrabel' ◽  
Jozef Beňo
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Rake Angle ◽  
Simulation Software ◽  
Tool Geometry ◽  
Element Method

In this paper, a Lagrangian finite element-based machining model is applied in the simulation of cutting forces in two-dimensional orthogonal cutting of titanium Ti-6Al-4V alloy. The simulations were conducted using 2D Finite Element Method (FEM) machining simulation software. In addition, the cutting experiments were carried out under the different cutting speed, feed and tool geometry (rake angle, clearance angle and cutting edge radius). The effect of cutting speed, feed and tool geometry on cutting force were investigated. The results obtained from the finite element method (FEM) and experimental studies were compared.

scholarly journals Mechanics of Machining With Chamfered Tools

1999 ◽  
Vol 122 (4) ◽  
pp. 650-659 ◽  
Author(s):  
H. Ren ◽  
Y. Altintas
Keyword(s):  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Minimum Energy ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Analytic Model

Chamfered cutting tools are used in high speed machining of hardened steels due to their wedge strength. An analytic model is proposed to investigate the influence of chamfer angle and cutting conditions on the cutting forces and temperature. The model is based on the tool geometry, cutting conditions, steady state temperature in the shear and chip-rake face contact zones, strain, strain rate, and the corresponding flow stress of the work material. With the aid of a slip line field model, the cutting and friction energy in the primary, secondary and chamfer zones are evaluated. By applying the minimum energy principle to total energy, the shear angle in the primary deformation zone is estimated. The corresponding shear strain, strain rate and flow stresses are identified. The model leads to the prediction of cutting forces and temperature produced in three deformation zones. The model is experimentally verified by high-speed orthogonal cutting tests applied to P20 mold steel using ISO S10 carbide and CBN cutting tools. It is shown that the analytic model is quite useful in selecting optimal chamfer angle and cutting speed which gives the minimum tool wear and relatively lower cutting forces. [S1087-1357(00)00204-5]

Numerical Modeling the Effect of Tool-Chip Friction in Orthogonal Cutting AISI4340

2010 ◽  
Vol 29-32 ◽  
pp. 1815-1819 ◽  
Author(s):  
Gang Tao Xu ◽  
Yu Sheng Li
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Clear Understanding ◽  
Workpiece Material ◽  
Explicit Finite Element ◽  
Plastic Model

A thermo-elastic-plastic model using explicit finite element code ABAQUS 6.8 was developed to investigate the effect of tool-chip friction in orthogonal cutting AISI4340. A.L.E finite element model was presented and the Johnson-Cook plastic model was used to model the workpiece material which is suitable for modeling cases with high strain, strain rate, strain hardening, and non-linear properties. In this paper, three different friction coefficient values of 0.2, 0.3, 0.4 were considered to study the effect on Cutting temperature, cutting forces and cutting stress. The results told a clear understanding of the effect of friction coefficient in orthogonal metal cutting, and larger friction coefficient induced higher cutting temperature, bigger cutting forces and larger cutting stress.

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