Mechanics of the Abrasive Cutoff Operation

1967 ◽  
Vol 89 (3) ◽  
pp. 495-502 ◽  
Author(s):  
M. C. Shaw ◽  
D. A. Farmer ◽  
K. Nakayama
Keyword(s):  
Grain Size ◽  
Wear Rate ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Wheel Speed ◽  
Point Of View ◽  
Wheel Wear ◽  
High Feed ◽  
Chip Size

The abrasive cutoff operation in which a high-speed disk is fed radially into a steel member is analyzed. The feed rate and the wheel speed are the chief variables of importance. Cutting forces and wheel wear rate are analyzed in terms of chip size, grain spacing, and the length of work in the direction of cut. While the highest wheel speed possible should be used, there is an optimum feed rate. When the feed rate is low, an excessive wheel temperature is encountered, and wheel wear rate will be high. At a high feed rate, individual chips are too large for the space available, and wheel wear will also be high. Best performance from the point of view of wheel wear rate is obtained using a hard, dense wheel of large grain size (20 or coarser) operating at the highest wheel speed possible and with an intermediate feed rate.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

scholarly journals Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

2020 ◽  
Vol 5 (2) ◽  
pp. 50-54
Author(s):  
Muataz Al Hazza ◽  
Khadijah Muhammad
Keyword(s):  
Statistical Analysis ◽  
Wear Rate ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis.  JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

Research on the Machining Behaviors in High Speed Milling Cellular Aluminium Alloy

2012 ◽  
Vol 472-475 ◽  
pp. 1087-1090
Author(s):  
Fa Zhan Yang ◽  
Xin Zhuang ◽  
Wan Hua Zhao ◽  
Yong Yang
Keyword(s):  
Aluminium Alloy ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Parameters ◽  
Point Of View ◽  
Element Analysis ◽  
Measuring Device ◽  
Tool Wear Mechanisms ◽  
Experimental Cutting ◽  
Cemented Carbide Tools

The purpose of this investigation is to examine the machining behavior of cemented carbide tools in dry hard milling of cellular aluminium alloy (6N01) by experiments and finite-element analysis. From the machining point of view, Cellular aluminium alloy are often considered as poor machinability materials. Milling tests were carried out by using a three-head milling machine and a milling force measuring device. For this purpose, both microscopic and microstructural aspects of the tools were taken into consideration. Meanwhile, the cutting forces and the noise intensity are also considered in the experiment. Results show that cutting forces vary greatly with the experimental cutting parameters. Additionally, the noise field intensity increased greatly as the feed rate increased. Analysis indicated that the major tool wear mechanisms observed in the machining tests involve adhesive wear and abrasion wear.

scholarly journals Impact of Cutting Forces and Chip Microstructure in High Speed Machining of Carbon Fiber – Epoxy Composite Tube

2017 ◽  
Vol 62 (3) ◽  
pp. 1771-1777 ◽  
Author(s):  
Y. Allwin Roy ◽  
K. Gobivel ◽  
K.S. Vijay Sekar ◽  
S. Suresh Kumar
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
The Impact ◽  
Thrust Forces

AbstractCarbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces) and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.

scholarly journals Taguchi parametric study on the radial and tangential cutting forces in Dry High Speed Machining (DHSM)

10.30544/472 ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 303-316
Author(s):  
M. Hatami ◽  
H. Safari
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Parametric Study ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Machining ◽  
Cutting Speeds

In this paper, L8 Taguchi array is applied to find the most important parameters effects on the radial and tangential cutting forces of a Ti–6Al-4V ELI titanium alloy in dry high speed machining (DHSM). The experiments are performed in four cutting speeds of 150, 200, 250, and 300 m/min and two feed rates of 0.03 and 0.06 mm/rev. Also, two cutting tools in types of XOMX090308TR-ME06 of uncoated (H25) and TiAlN+TiN coated (F40M) are used. Results confirm that to minimize the resultant cutting force and radial cutting force, utilizing the lower feed rate and higher cutting speeds were considered as the best levels of factors to reach to its goal.

Wear mechanisms of TiN-coated CBN tool during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (4) ◽  
pp. 553-566 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Wear Rate ◽  
Feed Rate ◽  
Wear Mechanisms ◽  
High Speed ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Die Steel

The aim of the present investigation was to identify the wear mechanisms of TiN-coated CBN tools prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed were abrasion wear at low cutting speed, low feed rate, and high workpiece hardness; formation of a transferred layer resulting from tribochemical reactions between constituents of the tool and workpiece material at high speed; and the formation of built-up edges at moderate cutting speed. Hard carbide particles of the work material at higher feed rate severely abraded the tool flank land, resulting in shallow grooves due to the detachment of CBN grains. At greater depth of cut, the built-up edges and transferred layer reduced friction and tool wear. Excessive adhesion of workpiece material followed by plastic deformation and notching were clearly visible at low workpiece hardness (47 HRC). The influence of cutting speed, feed rate, depth of cut, and workpiece hardness on the progressive tool flank wear, i.e. flank wear rate (VBr, μm/mm) in the steady wear region, was also analysed. The flank wear rate was observed to decrease with increase in cutting speed, depth of cut, and workpiece hardness, but after an initial decrease it increased with increase in feed rate.

Influences of Varying Combination of Feed Rate and Depth of Cut to Tool Wear Rate and Surface Roughness: High Speed Machining Technique in Non-High Speed Milling Machine

2014 ◽  
Vol 903 ◽  
pp. 194-199
Author(s):  
Mohd Zairulnizam Zawawi ◽  
Mohd Ali Hanafiah Shaharudin ◽  
Ahmad Rosli Abdul Manaf
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Tool Wear Rate

Machining technique using high spindle speed, high feed rate and shallow depth of cut utilize in High Speed Milling (HSM) machines offer several benefits such as increase of productivity, elimination of secondary and semi-finishing process, reduce tool load and small chips produced. By adjusting some of the machining parameters, non-HSM machine having lower spindle speed and feed rate could also take advantages some of the benefits mentioned above when applying the HSM technique. This experiment investigate the effects of varying combination of depth of cut and feed rate to tool wear rate and surface roughness during end milling of Aluminum and P20 tool steel in dry condition. The criterion for tool wear before it gets rejected is based on maximum flank wear, Vb of 0.6mm. Material removal rate, spindle speed and radial depth of cut are constant in this experiment. After preliminary machining trials, the combination starts with depth of cut of 2mm and feed rate of 45mm/min until the smallest depth of cut and highest feed rate of 0.03mm and 3000mm/min respectively. The obtained result shows that for both materials, feed rate significantly influences the surface roughness value while depth of cut does not as the surface roughness value keep increasing with the increase of feed rate and decreasing depth of cut. Whereas, tool wear rate almost remain unchanged indicates that material removal rate strongly contribute the wear rate. With no significant tool wear rate, this study demonstrates that HSM technique is possible to be applied in non-HSM machine with extra benefits of eliminating semi-finishing operation, reducing tool load for finishing, machining without coolant and producing smaller chip for ease of cleaning.

Ultrahigh Speed Micromachining

2010 ◽  
Author(s):  
Said Jahanmir
Keyword(s):  
Aluminum Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
Extended Period ◽  
Contact Forces ◽  
Micro Milling ◽  
Dental Ceramics ◽  
Diamond Grit ◽  
High Feed

A new ultrahigh speed micro-spindle has been developed for micromachining that can be used at rotational speeds as high as 500,000 rpm. Since conventional ball bearings or fluid lubricated journal bearings cannot be used at speeds beyond 300,000 rpm for any extended period of time, the new spindle uses a set of journal and thrust foil bearings. The micro-spindle was integrated with a 3-axis micro-milling machine. Cutting experiments were performed on an aluminum alloy at speeds greater than 300,000 rpm using 50 and 300 micron end-mills. The increase in rotational speed to 450,000 rpm in micro-milling of aluminum alloy allowed an increase in feed rate to nearly 800 mm/min (the maximum feed rate available by the positioning stage), thus increasing the material removal rate by more than two orders of magnitude. The dimensional accuracy of several straight cuts made at different feed rates and depths of cut was measured. Theoretical models and research on machining of industrial ceramics have shown that high-speed machining allows for smaller depths of cut by each diamond grit, thus reducing the contact forces and resulting in a reduced possibility of detrimental chipping and subsurface machining damage. Therefore, micro-grinding was performed on dental ceramics to evaluate the feasibility ultrahigh speed machining. In these studies several ceramics used for preparation of dental restorations were cut with diamond tools. The propensity for generation of machining-related damage, such as surface and subsurface microcracks, were greatly reduced by machining at ultrahigh speeds and high feed rates. Micro-machining at such high speeds, and in combination with high feed rates, has never been achieved before.

The Grinding Mechanism on Quick-Point Grinding Wheel Wear and Effects on Surface Quality

2009 ◽  
Vol 416 ◽  
pp. 370-374 ◽  
Author(s):  
Ya Dong Gong ◽  
Jian Qiu ◽  
Yu Jiao Liu ◽  
Jun Cheng ◽  
Fan Xu
Keyword(s):  
Wear Rate ◽  
Great Influence ◽  
Wheel Speed ◽  
Grinding Wheel ◽  
Cutting Depth ◽  
Wheel Wear ◽  
Wear Model ◽  
Wear Process ◽  
Grinding Wheel Wear ◽  
Grinding Mechanism

A study on the wear of Quick-point grinding wheel was carried on. The wheel wear was found having great influence on grinding performance and grinding quality. After analyzed the wear process and mechanism in Quick-point grinding, it was found the wear rate was directly related to some factors such as wheel width, workpiece speed, feed rate and Quick-point grinding angle, and it was indirectly affected by wheel speed and cutting depth. By means of some wear criteria, the wheel wear was able to be predicted. Furthermore, a wear model in wheel’s accurate area has been built up.

High Speed Grinding of Silicon Nitride With Electroplated Diamond Wheels: II — Wheel Topography and Grinding Mechanisms

1999 ◽  
Author(s):  
T. W. Hwang ◽  
C. J. Evans ◽  
S. Malkin
Keyword(s):  
Silicon Nitride ◽  
Contact Pressure ◽  
High Speed ◽  
Wheel Speed ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Flat Area ◽  
Abrasive Grains ◽  
Wheel Topography ◽  
High Speed Grinding

Abstract This is the second in a series of two papers concerned with high speed grinding of silicon nitride with electroplated diamond wheels. In the first paper (Hwang et al., in press), it was shown that grinding of silicon nitride is accompanied by dulling of the abrasive grains and a significant increase in the grinding forces and power. High wheel speed caused more wheel wear, which was attributed to a longer accumulated sliding length between the abrasive grains and the workpiece. This second paper is concerned with the progressive change in wheel topography during grinding and how it affects the grinding process. A statistical model is developed to characterize the wheel topography during grinding in terms of active cutting grains and wear flat area. According to this model, continued grinding is accompanied by an increase in both the number of active grains and the wear flat area on the wheel surface as the wheel wears down. The measured increase in grinding forces and power was found to be proportional to the wear flat area, which implies a constant average contact pressure and friction coefficient between the wear flats and the workpiece. Increasing the wheel speed from 85 m/s to 149 m/s significantly reduced the contact pressure, which may be attributed to a reduction of the interference angle, but had almost no effect on the attritious wear rate of the diamond abrasive. Therefore, more rapid wear of the diamond wheel at higher wheel speeds due to a longer sliding length may be offset by reduced contact pressures and lower grinding forces.

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