Forces on a Worn Cutting Tool

1961 ◽  
Vol 83 (4) ◽  
pp. 505-509 ◽  
Author(s):  
H. T. McAdams ◽  
Paul Rosenthal
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Removal Rate ◽  
Single Point ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Land Area ◽  
Constant Depth ◽  
Feed Force ◽  
Stock Removal

The forces on a single-point cutting tool under conditions of progressive flank wear are analyzed under the assumptions of constant rake, friction, and shear angle. Relations between wear land area and stock removal rate are derived for the case of constant feed force. For the case of constant depth of cut, the relation between wear land area and feed force is developed.

Effect of Microwave Sintering Treatment to the Flank Wear of Titanium Carbide Tools in Milling Operations

2015 ◽  
Vol 1115 ◽  
pp. 59-63
Author(s):  
Mohammad Iqbal ◽  
Tasnim Firdaus Ariff ◽  
Mohd Shahrul Fahmi bin Mat Roseh ◽  
Muataz Hazza Faizi Al-Hazza ◽  
Irfan Hilmy ◽  
...  
Keyword(s):  
Titanium Carbide ◽  
Cutting Tool ◽  
Flank Wear ◽  
Microwave Sintering ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Machining Time ◽  
Milling Operations ◽  
The Face

The paper reports the research on the improvement of tool wear resistant of Titanium Carbide (TiC) cutting tool after microwave post sintering treatment. Titanium Carbide square milling insert was microwave sintered at 600°C with 15 minutes of holding time. The face milling operations were conducted to Carbon Steel S45C block (130 mm x 95 mm x 40 mm) by using both of original and microwave sintered insert at 5 different cutting speed (60, 90 , 120 , 150 and 180 m/min), constant feed rate (0.2 mm/tooth) and constant depth of cut (0.2 mm/tooth). The flank wear of the insert was measured every nearest 10th minute of complete cutting passes. The results of the experiment show that microwave post sintering treatment improves the tool resistant of the TiC insert. The flank wear of the sintered insert is lower at any machining time and all cutting speed. The research also found that the percentage of the improvement is lower at higher cutting speed compare to lower cutting speed.

Grinding Process Size Effect and Kinematics Numerical Analysis

1999 ◽  
Vol 122 (1) ◽  
pp. 59-69 ◽  
Author(s):  
William L. Cooper ◽  
Adrienne S. Lavine
Keyword(s):  
Steady State ◽  
Removal Rate ◽  
Empirical Relationship ◽  
Three Dimensional ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Zone Length ◽  
Abrasive Grains ◽  
Three Dimensional Modeling ◽  
Stock Removal

The present work developed numerical codes that simulate steady-state grinding process kinematics. The three-dimensional modeling procedure entails the following: specifying the sizes, shapes, and positions of individual abrasive grains on the wheel surface; geometrically calculating the abrasive grains’ depth of cut distributions along the grinding zone as they pass through the grinding zone (neglecting wheel, abrasive grain, and workpiece deflections); using an empirical relationship to relate the abrasive grains’ geometric depths of cut to the grains’ actual depths of cut; and updating the workpiece surface to account for material removal. The resulting data include the abrasive grains’ average depth of cut distribution along the grinding zone, stock removal depth, stock removal rate, grinding zone shape, grinding zone length, percentage of grains impacting the workpiece, grain-workpiece impact frequency, etc. The calculated grinding zone lengths compare favorably with experimental data. This article examines a number of steady-state grinding processes. [S1087-1357(00)00101-5]

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Grey-Based Taguchi Analysis Approach for Optimization of Multi-Objective Problem

2014 ◽  
pp. 219-239
Author(s):  
Nirmal S Kalsi ◽  
Rakesh Sehgal ◽  
Vishal S. Sharma
Keyword(s):  
Feed Rate ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Analysis Technique ◽  
Grey Relation

Due to the increase in complexity and expectations of more reliable solutions for a problem, the importance of multi-objective problem solutions is increasing day by day. It can play a significant role in making a decision. In the present approach, many combinations of the optimization techniques are proposed by the researchers. These hybrid evolutionary methods integrate positive characteristics of different methods and show the advantage to reach global optimization. In this chapter, Taguchi method and the GRA (Grey Relation Analysis) technique are pronounced and used to optimize a multi-objective metal cutting process to yield maximum performance of tungsten carbide-cobalt cutting tool inserts in turning. L18 orthogonal array is selected to analyze the effect of cutting speed, feed rate, and depth of cut using cryogenically treated and untreated inserts. The performance is evaluated in terms of main cutting force, power consumption, tool wear, and material removal rate using main effect plots of S/N (Signal to Noise) ratios. This chapter indicates that the grey-based Taguchi technique is not only a novel, efficient, and reliable method of optimization, but also contributes to satisfactory solution for multi-machining objectives in the turning process. It is concluded that cryogenically treated cutting tool inserts perform better. However, the feed rate affects the process performance most significantly.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

Single Point Diamond Turning of Silicon by Using Micro-Laser Assisted Machining Technique

2014 ◽  
Author(s):  
Hossein Mohammadi ◽  
H. Bogac Poyraz ◽  
Deepak Ravindra ◽  
John A. Patten
Keyword(s):  
Fiber Laser ◽  
Cutting Tool ◽  
Single Point ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Beam Diameter ◽  
Diamond Cutting ◽  
Laser Assisted Machining ◽  
Diamond Cutting Tool ◽  
Si Wafer

In this study, single point diamond turning (SPDT) is coupled with the micro-laser assisted machining (μ-LAM) technique. The μ-LAM system is used to preferentially heat and thermally soften the work piece material in contact with a diamond cutting tool. In μ-LAM the laser and cutting tool are integrated into a single package, i.e. the laser energy is delivered by a single mode fiber laser to and through a diamond cutting tool. This hybrid method can potentially increase the critical depth of cut (DoC), i.e., a larger ductile-to-brittle transition (DBT) depth, in ductile regime machining, resulting in a higher material removal rate (MRR). An IR continuous wave (CW) fiber laser, wavelength of 1064nm and max power of 100W with a beam diameter of 10μm, is used in this investigation. In the current study SPDT tests were employed on single crystal silicon (Si) wafer which is very brittle and hard to machine by conventional methods. Different outputs such as surface roughness and depth of cut for different set of experiments were analyzed. Results show that an unpolished surface of a Si wafer can be machined in one pass to get a very good surface finish. The Ra was brought down from 1.2μm to 275nm only in one pass which is a very promising result for machining the Si wafer.

Research on Microscopic Grain-Workpiece Interaction in Grinding through Micro-Cutting Simulation, Part 2: Factorial Study

2009 ◽  
Vol 76-78 ◽  
pp. 15-20 ◽  
Author(s):  
Lan Yan ◽  
Xue Kun Li ◽  
Feng Jiang ◽  
Zhi Xiong Zhou ◽  
Yi Ming Rong
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Specific Cutting Force ◽  
Single Grain

The grinding process can be considered as micro-cutting processes with irregular abrasive grains on the surface of grinding wheel. Single grain cutting simulation of AISI D2 steel with a wide range of cutting parameters is carried out with AdvantEdgeTM. The effect of cutting parameters on cutting force, chip formation, material removal rate, and derived parameters such as the specific cutting force, critical depth of cut and shear angle is analyzed. The formation of chip, side burr and side flow is observed in the cutting zone. Material removal rate increases with the increase of depth of cut and cutting speed. Specific cutting force decreases with the increase of depth of cut resulting in size effect. The shear angle increases as the depth of cut and cutting speed increase. This factorial analysis of single grain cutting is adopted to facilitate the calculation of force consumption for each single abrasive grain in the grinding zone.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Machinability Study Using Chip Thickness Ratio on Difficult to Cut Metals by CBN Cutting Tool

2012 ◽  
Vol 504-506 ◽  
pp. 1317-1322 ◽  
Author(s):  
Sivaprakasam Thamizhmanii ◽  
Hasan Sulaiman
Keyword(s):  
Stainless Steel ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cubic Boron Nitride ◽  
Chip Thickness ◽  
Shear Angle ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Alloy Steels

Machinability is the one of the criteria in determining the life of the cutting tool. In this experiment, hard and difficult to cut materials like hard AISI 440 C stainless steel and hard SCM 440 alloy steels were discussed. However, machinability of the material is considered to be poor due to its inherent characteristics. The machinability studies on AISI 440 C stainless steel and SCM 440 alloy steels had not been carried out by researchers. Machinability indices used in such cases have the characteristics such as cutting force, surface roughness, tool wear etc. In the case of high-speed machining of said materials machinability indices such as chip thickness (RC), shear angle (Ф), surface integrity, and chip analysis are of prime importance. Most of the researchers have not given due consideration to these vital machinability indices necessary for understanding of high-speed cutting of said materials. In this work, an experimental investigation was carried out to understand the behavior of difficult to cut materials, when machined with Cubic Boron Nitride (CBN) insert tool. The results and analysis of this work indicated that the above-mentioned machinability indices are important and necessary to assess the machinability of said materials effectively. The operating parameters used were cutting velocity 100, 125, 150, 175 and 200 m/min with feed rate of 0.10, 0.20 and 0.30 mm rev-1 with constant depth of cut of 1.0 mm. The length of turning was 150 mm and 300 mm. Machinability of both materials and tool was evaluated in terms of roughness, flank wear, cutting force, chip thickness ratio and shear angle.

Optimal flank wear in turning of Inconel 625 super-alloy using ceramic tool

2016 ◽  
Vol 232 (2) ◽  
pp. 208-216 ◽  
Author(s):  
M Jahanbakhsh ◽  
A Akhavan Farid ◽  
Mohammad Lotfi
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition

Rapid tool wear is one of the major machinability aspects of nickel-based super alloys. In this article, the effect of cutting parameters on material removal rate and tool wear of a whisker ceramic insert in turning of Inconel 625 was examined. Optical microscope and scanning electron microscope were applied to measure and study tool wear mechanism. Response surface method was used to develop a mathematical model which confirmed by experimental tests. The statistical analysis done by analysis of variance showed that depth of cut is the most effective factor on the tool wear. Experiments showed that increment of feed rate had an insignificant effect on the progress of flank wear, and it is an important controlling factor when material removal rate is considered as a desired output. Finally, optimized cutting condition is presented in this work.

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