scholarly journals Erratum: “Material Characterization for Metal-Cutting Force Modeling” (Journal of Engineering Materials and Technology, 1989, 111, pp. 210–219)

1989 ◽  
Vol 111 (3) ◽  
pp. 242-242 ◽  
Author(s):  
D. A. Stephenson
Keyword(s):  
Cutting Force ◽  
Material Characterization ◽  
Metal Cutting ◽  
Force Modeling ◽  
Engineering Materials

Stochastic Cutting Force Modeling and Prediction in Machining

2020 ◽  
Vol 142 (12) ◽  
Author(s):  
Yang Liu ◽  
Zhenhua Xiong ◽  
Zhanqinag Liu
Keyword(s):  
Stochastic Model ◽  
Cutting Force ◽  
Metal Cutting ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Force Modeling ◽  
Cutting Coefficients ◽  
Machining System ◽  
Set Up ◽  
Multi Mode

Abstract As the cutting force plays an important role in machining, the modeling of cutting force has drawn considerable interests in recent years. However, most of current methods were focused on the deterministic modeling of cutting force, while the inherent stochasticity of cutting force is rarely considered for general metal cutting machining. Thus, a stochastic model is proposed in this paper to predict the stochastic cutting force by considering realistic cutting conditions, including the inhomogeneity of cutting material and the multi-mode machining system. Specifically, we transform the constant cutting coefficient in previous models into a stationary Gaussian process in the proposed stochastic model. As for the tool vibration, the uncut chip thickness is also modeled in a stochastic manner. Moreover, it is found that the random cutting coefficients can be estimated conveniently through experiments and effectively simulated by stochastic differential equations at any timescale. Then, the stochastic cutting force can be predicted numerically by combining the stochastic model and the multi-mode dynamic equations. For verification, a three-mode machining system was set up, and workpieces with different metal alloys were tested. It is found that the random cutting coefficients estimated are insensitive to cutting parameters, and the prediction results show satisfactory agreement with experimental results in both time and statistical domains. The proposed method can provide rich statistical information of cutting forces, which can facilitate related applications like tool condition monitoring when the on-line measurement of cutting force is not preferred or even impossible.

Analytical cutting force modelling of micro-slot grinding considering tool-workpiece interactions on both primary and secondary tool surfaces

2021 ◽  
pp. 1-43
Author(s):  
Ashwani Pratap ◽  
Karali Patra
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Surface Interactions ◽  
Surface Interaction ◽  
Edge Density ◽  
Force Model ◽  
Height Distribution ◽  
Force Modeling ◽  
Tool Surface

Abstract This work presents an analytical cutting force modeling for micro-slot grinding. Contribution of the work lies in the consideration of both primary and secondary tool surface interactions with the work surface as compared to the previous works where only primary tool surface interaction was considered during cutting force modeling. Tool secondary surface interaction with workpiece is divided into two parts: cutting/ ploughing by abrasive grits present in exterior margin of the secondary tool surface and sliding/adhesion by abrasive grits in the inner margins of the secondary tool surface. Orthogonal cutting force model and indentation based fracture model is considered for cutting by both the abrasives of primary tool surface and the abrasives of exterior margin on the secondary surface. Asperity level sliding and adhesion model is adopted to solve the interaction between the workpiece and the interior margin abrasives of secondary tool surface. Experimental measurement of polycrystalline diamond tool surface topography is carried out and surface data is processed with image processing tools to determine the tool surface statistics viz., cutting edge density, grit height distribution and abrasive grit geometrical measures. Micro-slot grinding experiments are carried out on BK7 glass at varying feed rate and axial depths of cut to validate the simulated cutting forces. Simulated cutting forces considering both primary and secondary tool surface interactions are found to be much closer to the experimental cutting forces as compared to the simulated cutting forces considering only primary tool surface interaction.

scholarly journals KINEMATICS OF METALLURGICAL CUTTERS WITH PARALLEL BLADES

2019 ◽  
Vol 62 (4) ◽  
pp. 308-314
Author(s):  
I. V. Bychkov ◽  
L. T. Dvornikov ◽  
I. A. Zhukov
Keyword(s):  
Cutting Force ◽  
Kinematic Analysis ◽  
Metal Cutting ◽  
Vertical Plane ◽  
Special Method ◽  
Kinematic Scheme ◽  
Maximal Force ◽  
Metal Separation ◽  
Entire Thickness ◽  
Roller Bed

Cutting with parallel blades cutters consists of three periods: blades ridging in metal; cutting; chipping (separation). Maximum force is required at the end of the ridging period and at the beginning of cutting. Since one of the blades is stationary, the second blade in cutting process has to go deep into the entire thickness of metal to cut the billet. For example, if thickness of metal is20 mm, then the upper blade needs to pass20 mmfor its cutting. If you make both blades moving towards each other, cutting effort will be less. In this case, each blade cutting20 mmof metal will pass 10mm. In order not to make mechanism of cutter with two movable blades too complicated, it is important to ensure its mobility from one drive. So, there acute the issue of arrangement possibility of blades moving towards each other with guaranteed strength of the units, transmitting effort on the blades. Kinematic scheme of cutters with blades moving parallel to each other in a vertical plane is proposed. Advantages of the proposed cutters design are the following: counter movement of blades requires less effort to cut the billet; force from each blade is distributed to two connecting rods, reducing load on each of them; since blades move towards each other, the main cutting force is distributed along the units of the mechanism and is transmitted to the engine, which reduces load on the frame and foundation when cutting; when blades move towards each other, metal separation occurs faster, it allows to concentrate maximal force during cutting with minimal load on the engine; the cut part of the billet does not fall below the roller bed at the end of cutting, so installation of the lower movable table is not required. Mobility of the proposed mechanism is determined by P.L. Chebyshev formula with its value = 1. Kinematic analysis of blades is carried out using a special method, which is in using point of connecting rods intersection.

Cutting Force Modeling

2019 ◽  
pp. 417-432
Author(s):  
Karla P. Monroy Vazquez ◽  
Claudio Giardini ◽  
Elisabetta Ceretti
Keyword(s):  
Cutting Force ◽  
Force Modeling

Assessment of the Adequacy of the Definition of Cutting Forces for the Purpose of Minimizing Energy Consumption in Machining Processes

2019 ◽  
Vol 945 ◽  
pp. 556-562
Author(s):  
A.G. Kondrashov ◽  
D.T. Safarov ◽  
R.R. Kazargeldinov
Keyword(s):  
Energy Consumption ◽  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Electrical Power ◽  
Cutting Tools ◽  
Precise Determination ◽  
Machining Processes ◽  
Milling Operations ◽  
Cutting Equipment

Minimizing energy consumption in the processing of parts on metal-cutting equipment is most effective at the stage of designing the content of operations. Important in this process is the precise determination of the initial parameters - cutting forces. This parameter allows you to plan both energy consumption and perform additional calculations for the deformation of the tooling and workpiece in order to predict the geometric accuracy of the machined part. The article presents the results of experiments on measuring the circumferential cutting force during milling operations of an aluminum alloy workpiece with an end mill. The measurements were carried out by an indirect method - by recording the electrical power on the spindle and then calculating the circumferential cutting force. Theoretical analysis of the methods of calculation of cutting forces showed significant differences between the results obtained by domestic methods and recommendations of world manufacturers of cutting tools. Statistical analysis of the results of calculations based on reference data and measurements made it possible to assess the adequacy of the known methods for calculating cutting forces in order to minimize energy consumption in operations of processing parts on metal-cutting equipment

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

Modeling and Simulation of Process and Structure Interactions Considering Turning Operations

2009 ◽  
Author(s):  
Michael F. Zaeh ◽  
Florian Schwarz
Keyword(s):  
Machine Tool ◽  
Cutting Force ◽  
Metal Cutting ◽  
Material Behavior ◽  
Force Model ◽  
Machine Tool Structure ◽  
Simulation Based ◽  
Turning Center ◽  
Simplifying Assumptions ◽  
Input Variables

A consideration of the dynamic interaction between the machine tool structure and the cutting process is required for the prediction and optimization of machining tasks through simulation. This paper outlines a modular, analytical cutting force model applicable to common turning processes. It takes into account the dynamic material behavior and nonlinear friction ratios on the rake face as well as heat transfer phenomena in the deformation zones. In order to overcome simplifying assumptions in analytical cutting force descriptions and to incorporate the chip formation process into the analysis, specific input variables are determined in a metal cutting simulation based on the Finite Element Method (FEM). On the machine tool structure side, the setup of a parametric FEM model is presented. The accuracy of both the machine tool and cutting force models was verified experimentally on a turning center.

Sign in / Sign up

Export Citation Format

Share Document