Tool Life in Oblique Cutting as a Function of Computed Flank Contact Temperature

1990 ◽  
Vol 112 (4) ◽  
pp. 307-312 ◽  
Author(s):  
P. K. Venuvinod ◽  
W. S. Lau ◽  
C. Rubenstein
Keyword(s):  
Tool Life ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Contact Temperature ◽  
Tool Geometry ◽  
Heat Sources ◽  
Oblique Cutting ◽  
Contact Points ◽  
Discrete Contact ◽  
Using Data

The steps by which a tool life analysis applicable to orthogonal cutting can be extended to accommodate tool obliquity are detailed. By following these, a relation between tool-life, T, tool obliquity, λ, and a representative tool flank wear land contact temperature, θfs, is obtained. A method is then described by which θfs in oblique cutting can be computed. This is based on a recently developed procedure for estimating temperatures of obliquely moving heat sources on the rake face combined with the influence of constriction resistance occurring at the discrete contact points within the flank contact area. In this way, from a knowledge of the T − θfs relation applicable to a given tool/workpiece combination cut orthogonally, tool lives at different tool obliquities are predicted and are shown to agree quite well with experimentally determined values. Finally, a comprehensive tool life expression independent of cutting parameters and of tool geometry is proposed and is verified using data obtained by cutting mild steel with H.S.S. tools.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Mechanism of Chip Deformation in Orthogonal Cutting the Wheel Steel

2008 ◽  
Vol 375-376 ◽  
pp. 26-30
Author(s):  
Kai Xue ◽  
Xiang Ming Xu ◽  
Gang Liu ◽  
Ming Chen
Keyword(s):  
Chip Formation ◽  
Feed Rate ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Wheel Steel ◽  
Tool Geometry ◽  
Orthogonal Turning ◽  
On Chip

The chip formation and morphology are definitely affected by tool geometry and cutting parameters such as cutting speed, feed rate, and depth of cutting. An experiment investigation was presented to study the influence of tool geometry on chip morphology, and to clarify the effect of different cutting parameters on chip deformation in orthogonal turning the wheel steel. The result obtained in this study showed that tool geometry affected the chip morphology significantly; cutting speed was the most contributive factor in forming saw-tooth chip.

scholarly journals A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4074 ◽  
Author(s):  
Víctor Criado ◽  
Norberto Feito ◽  
José Luis Cantero Guisández ◽  
José Díaz-Álvarez
Keyword(s):  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Linear Displacement ◽  
Tool Geometry ◽  
Cfrp Laminates ◽  
Reinforced Plastics ◽  
Wide Range ◽  
Cutting Speeds

Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

scholarly journals An Investigation of Tool Performance in Interrupted Turning of Inconel 718

2018 ◽  
Vol 237 ◽  
pp. 02008
Author(s):  
Tadeusz Chwalczuk ◽  
Martyna Wiciak ◽  
Agata Felusiak ◽  
Piotr Kieruj
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Burr Size ◽  
Tool Performance ◽  
Interrupted Turning

The paper presents the result of an investigation of cemented carbides cutting tools performance in interrupted turning of Inconel 718. The discussion is based on case study revealed from industry experience. The spacing created for operational reasons cause interruption in turning process what has crucial effect on tool life and wear. Furthermore cutting parameters and tool geometry have significant influence on creating burr at the edge of spacing which leads dimensional deviation. The research based on two stages, preliminary and modelling, was introduced. In the first an effect of cutting speed, feed, depth of cut, rake angle and tool major cutting edge angle on wear and burr size was investigated. The second step was a regression based modelling of major parameter influence on various process aspects such as values of forces, tool wear and burr size. It was found that the consequential effect on plastic deformation of edge and tool performance have depth of cut. It also has been proven that higher cutting speed, lower values of angles provides better quality of machined element. The paper gives recommendations for turning parameters selection to acceptable burr forms, tool life and process performance.

scholarly journals Phenomenological Study of Multivariable Effects on Exit Burr Criteria During Orthogonal Cutting of AlSi Alloys Using Principal Components Analysis

2018 ◽  
Vol 140 (10) ◽  
Author(s):  
Tristan Régnier ◽  
Guillaume Fromentin ◽  
Alain D'Acunto ◽  
José Outeiro ◽  
Bertrand Marcon ◽  
...  
Keyword(s):  
High Speed ◽  
Laser Scanning ◽  
Phenomenological Study ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Experimental Methodology ◽  
Burr Formation ◽  
Tool Geometry ◽  
Exit Burr

During machining, burrs are produced along a part's edges, which can affect a final product lifetime or its efficiency. Moreover, time-consuming and expensive techniques are needed to be applied to remove such burrs. Therefore, companies attempt to reduce burrs formation during machining by manipulating the cutting conditions. This study aims to analyze and quantify the effect of a wide number of parameters on burr formation, resulting from different mechanisms, during orthogonal cutting of AlSi alloys. A highly developed experimental methodology combining high-speed camera recording, laser scanning, and in situ deburring system is used for this study. A statistical analysis is then applied to evaluate relations between controlled parameters and the occurrence of exit burrs morphologies. The results show that the uncut chip thickness influences burr types distribution along the exit edge and chamfer geometry. Among the cutting parameters and tool geometry, tool rake angle is the main parameter affecting burr height. Finally, it is found that none of the burrs geometrical characteristics ranges are piloted by cutting parameters or tool geometry. The assumption of a possible microstructural influence on these outputs is made.

Investigation on the Cutting Performance of a New Kind of Nickel-Based Super Alloy

2006 ◽  
Vol 315-316 ◽  
pp. 220-224
Author(s):  
D.L. Wang ◽  
Y.Q. Kong
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Empirical Formulas ◽  
New Material ◽  
Drilling Operations ◽  
Cutting Experiment ◽  
Super Alloy

The design for orthogonal cutting experiment is made according to the characteristics of a new kind of nickel-based super alloy. The machinability of this new material in milling and drilling operations, including cutting force and tool wear, has been researched through experiments and then the empirical formulas of cutting force in milling and drilling have been presented. The research is useful in selecting the tool geometry and cutting parameters for machining the new material in practice.

An Experimental Investigation of the Influence of Cutting-Edge Geometry on the Machinability of Compacted Graphite Iron

2013 ◽  
Vol 3 (1) ◽  
pp. 1-25 ◽  
Author(s):  
Varun Nayyar ◽  
Md. Zubayer Alam ◽  
Jacek Kaminski ◽  
Anders Kinnander ◽  
Lars Nyborg
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Tool Geometry ◽  
Compacted Graphite Iron ◽  
Compacted Graphite ◽  
Edge Geometry ◽  
Area Of Interest

Compacted graphite iron (CGI) is considered as the potential replacement of flake graphite iron (FGI) for the manufacturing of new generation high power diesel engines. Use of CGI, that have higher strength and stiffness as compared to FGI, allows engine to perform at higher peak pressure with higher fuel efficiency and lower emission rate. However, not only for its potential, CGI is of an area of interest in metal cutting research because of its poor machinability as compared to that of FGI. The higher strength of CGI causes a faster tool wear rate in continuous machining operation even in low cutting speed as compared to that for FGI. This study investigated the influence of cutting edge geometry at different cutting parameters on the machinability of CGI in terms of tool life, cutting force and surface roughness and integrity in internal turning operation under wet condition. It has been seen that the cutting edge radius has significant effect on tool life and cutting forces. The results can be used to select optimum cutting tool geometry for continuous machining of CGI.

Numerical analysis of heat flow in oxy-ethylene flame cutting of steel plate

2016 ◽  
Vol 232 (4) ◽  
pp. 742-751 ◽  
Author(s):  
Kang-Yul Bae ◽  
Young-Soo Yang ◽  
Myung-Su Yi ◽  
Chang-Woo Park
Keyword(s):  
Numerical Simulation ◽  
Heat Flow ◽  
Heat Affected Zone ◽  
Steel Plate ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Heat Sources ◽  
Power Functions ◽  
Severe Problem ◽  
Ethylene Flame

To manufacture a steel structure, in the first step, raw steel plate needs to be cut into proper sizes. Oxy-fuel flame is widely used in the cutting process due to its flexibility with respect to accessibility, plate thickness, cost, and material handling. However, the deformation caused by the cutting process frequently becomes a severe problem for the next process in the production of steel product. To decrease the deformation, the thermo-elasto-plastic behavior of the steel plate in the cutting process should be analyzed in advance. In this study, heat sources in oxy-ethylene flame cutting of steel plate were modeled first, and the heat flow in the steel plate was then analyzed by the models of the heat sources using a numerical simulation based on the finite element method. To verify the analysis by the numerical simulation including the models, a series of experiments were performed, and the temperature histories at several points on the steel plate during the cutting process were measured. Moreover, the predicted sizes of the heat-affected zone by the numerical simulations according to the variation in the cutting parameters were compared to the experimental results. The power functions of the relationship between the sizes of the heat-affected zone and cutting parameters were obtained by the recursion analysis using the correlation between the results and parameters. The results of the numerical simulation showed good agreement with those of the experiments, indicating that the proposed models of the heat sources and thermal analysis were feasible to analyze the heat flow in the steel plate during the cutting process.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

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