Milling Forces Measured With a Planetary-Gear Torquemeter

1961 ◽  
Vol 83 (4) ◽  
pp. 579-586 ◽  
Author(s):  
J. R. Roubik
Keyword(s):  
Cutting Force ◽  
High Efficiency ◽  
Comparative Method ◽  
Cutting Speed ◽  
Planetary Gear ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Gear Design ◽  
Milling Forces ◽  
Force Data

Cutting-force data, obtained with a torquemeter of planetary-gear design in carbide milling tests on SAE-1018 cold-rolled steel at feeds from 0.002 to 0.030 in. per tooth, cutting speeds from 87 to 957 fpm, and depths of cut from 0.100 to 0.300 in. with a tool geometry of −7°, 0°, 3°, 5°, 0°, 15°, 1/64″ × 45°, are presented. The influences of variations in cutting speed, feed per tooth, and depth of cut on tangential cutting force are depicted graphically. Cutting-force values for other workpiece materials are also included. With these data a comparative method of experimentally verifying the computed high efficiency of the torquemeter itself is derived and applied. A method of obtaining highly accurate determinations of milling machine efficiency under actual oscillatory cutting loads is described with an example. Actual and theoretical traces of the variation of tangential cutting force with both single and multiple-toothed face milling cutters are illustrated for comparison.

scholarly journals On the Machinability Evolution in Asymmetric Milling of TC25 Ti Alloy Aiming at High Performance Machining

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7306
Author(s):  
Xueli Song ◽  
Hongshan Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
High Performance ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Balanced Development ◽  
Radial Depth ◽  
The Asymmetry

In this paper, the evolutions of cutting force, cutting temperature, and surface roughness, and the corresponding machinability in asymmetric up-milling of TC25 alloy are investigated. The results indicated that radial depth of cut generated opposite influence on the cutting force/cutting temperature versus surface roughness. The reason can be accounted as the intertwining of feed marks at low radial depth of cut, and the mechanism of hard cutting at a high radial depth of cut. Moreover, the asymmetry has a significant effect on the machinability in asymmetry up-milling TC25 alloy. Changing the asymmetry, i.e., the radial depth of cut, can alter the machinability while maintain the balanced development of various indexes. The machinability reaches the best when the radial depth of cut is ae = 8 mm. The axial depth of cut and feed per tooth should be selected as large as possible to avoid work hardening and to improve machining efficiency in asymmetric up-milling TC25 alloy. The cutting speed should be controlled within Vc = 100–120 m/min to obtain better machinability. On the basis of this research, it is expected to find optimized milling parameters to realize high efficiency milling of TC25 alloy.

The Combined Approach to the Evaluation of the Cutting Force Data when Ball End Milling

2014 ◽  
Vol 693 ◽  
pp. 352-357 ◽  
Author(s):  
Jozef Beňo ◽  
Jozef Stahovec ◽  
Ildikó Maňková ◽  
Marek Vrabeľ ◽  
Ladislav Kandráč
Keyword(s):  
Response Surface Methodology ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Combined Approach ◽  
Testing Conditions ◽  
Ball End Milling ◽  
Main Effects ◽  
Force Data

This paper introduces chosen results from measuring cutting forces when end ball milling as well as combined approach to their evaluation. Such a combined approach involves Taguchi array and Response Surface Methodology while main cutting data as depth of cut and side step and cutting speed and feed rate have been taken into account. Main effects of cutting data mentioned above have been identified by means of statistical formulae expressing testing conditions of ball end milling cutters. Interactions among all the cutting conditions are capable of finding out optimized radial and axial depth of cut which are derived from the measured components of the cutting force.

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 Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

Experimental study and multi-objective optimization of process parameters during turning of 100Cr6 using C-type advanced coated tools

2021 ◽  
pp. 095440622110431
Author(s):  
LR Bhandarkar ◽  
PP Mohanty ◽  
SK Sarangi
Keyword(s):  
Cutting Force ◽  
Distance Measure ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
X Ray ◽  
Coated Tools ◽  
Reduction Coefficient ◽  
Machining Parameter

The drive of this research is to examine the machinability of 100Cr6 bearing steel using advanced C-type cutting tools. Experimental studies investigated the effects of machining variables on the surface quality, chip reduction coefficient and cutting force. Seven advanced coated tools were checked for characterization by micro hardness (VHN), adhesion quality, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDXS). The experimental trials were planned by Taguchi’s L18 orthogonal array using a mixed-level design. Two numerical machining variables feed rate and cutting speed, and one categorical machining variable tool type was taken into consideration while a constant depth of cut was kept for all trails. A combined Taguchi-Satisfaction function distance measure approach was implemented for multi-response optimization. The most promising machining parameter setting for minimization of surface roughness, cutting force, and chip reduction coefficient was identified. The most important process parameter was found to be tool-type. Ceramics tools are found to be best trailed by WC coated tools under most of the conditions. Lower tool wear was observed in the CBN tool as compared to others.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

Application of MCDM-based TOPSIS method for the selection of optimal process parameter in turning of pure titanium

2017 ◽  
Vol 24 (7) ◽  
pp. 2009-2021 ◽  
Author(s):  
Akhtar Khan ◽  
Kalipada Maity
Keyword(s):  
Decision Making ◽  
Cutting Force ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Optimal Combination ◽  
Depth Of Cut ◽  
Topsis Method ◽  
Content Type ◽  
Cp Ti ◽  
Selection Of

Purpose The purpose of this paper is to explore a multi-criteria decision-making (MCDM) methodology to determine an optimal combination of process parameters that is capable of generating favorable dimensional accuracy and product quality during turning of commercially pure titanium (CP-Ti) grade 2. Design/methodology/approach The present paper recommends an optimal combination of cutting parameters with an aim to minimize the cutting force (Fc), surface roughness (Ra), machining temperature (Tm) and to maximize the material removal rate (MRR) after turning of CP-Ti grade 2. This was achieved by the simultaneous optimization of the aforesaid output characteristics (i.e. Fc, Ra, Tm, and MRR) using the MCDM-based TOPSIS method. Taguchi’s L9 orthogonal array was used for conducting the experiments. The output responses (cutting force: Fc, surface roughness: Ra, machining temperature: Tm and MRR) were integrated together and presented in terms of a single signal-to-noise ratio using the Taguchi method. Findings The results of the proposed methodology depict that the higher MRR with desirable surface quality and the lower cutting force and machining temperature were observed at a combination of cutting variables as follows: cutting speed of 105 m/min, feed rate of 0.12 mm/rev and depth of cut of 0.5 mm. The analysis of variance test was conducted to evaluate the significance level of process parameters. It is evident from the aforesaid test that the depth of cut was the most significant process parameter followed by cutting speed. Originality/value The selection of an optimal parametric combination during the machining operation is becoming more challenging as the decision maker has to consider a set of distinct quality characteristics simultaneously. This situation necessitates an efficient decision-making technique to be used during the machining operation. From the past literature, it is noticed that only a few works were reported on the multi-objective optimization of turning parameters using the TOPSIS method so far. Thus, the proposed methodology can help the decision maker and researchers to optimize the multi-objective turning problems effectively in combination with a desirable accuracy.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

scholarly journals Machining force comparison for surface defect hard turning and conventional hard turning of AISI 52100 steel

2021 ◽  
Vol 13 (3) ◽  
pp. 205-214
Author(s):  
P. U MAMAHESWARRAO ◽  
D. RANGARAJU ◽  
K. N. S. SUMAN ◽  
B. RAVISANKAR
Keyword(s):  
Hard Turning ◽  
Surface Defect ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Machining Force ◽  
Aisi 52100 Steel ◽  
The Impact

In this article, a recently developed method called surface defect machining (SDM) for hard turning has been adopted and termed surface defect hard turning (SDHT). The main purpose of the present study was to explore the impact of cutting parameters like cutting speed, feed, depth of cut, and tool geometry parameters such as nose radius and negative rake angle of the machining force during surface defect hard turning (SDHT) of AISI 52100 steel in dry condition with Polycrystalline cubic boron nitride (PCBN) tool; and results were compared with conventional hard turning (CHT). Experimentation is devised and executed as per Central Composite Design (CCD) of Response Surface Methodology (RSM). Results reported that an average machining force was decreased by 22% for surface defect hard turning (SDHT) compared to conventional hard turning (CHT).

Experimental Investigation of Mechanical-Thermal Characteristics in High Efficiency Turning Titanium Alloy Ti6Al4V

2016 ◽  
Vol 836-837 ◽  
pp. 20-28
Author(s):  
Li Min Shi ◽  
Cheng Yang ◽  
Qi Jun Li
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Thermal Characteristics ◽  
Tool Failure ◽  
Minimal Quantity Lubrication ◽  
Titanium Alloy Ti6al4v

Titanium alloy Ti6Al4V has poor machinability, which leads to high unit cutting force and cutting temperature, rapid tool failure. In this study, the effect of the cutting speed, feed rate and cooling condition on cutting force and cutting temperature is critically analysed by turning experiment. At the same time, the relationship is established among tool wear, cutting force and cutting temperature. This investigation has shown that cutting speed is the decisive factor which increasing cutting force and cutting temperature. In the process of turning, tool wear results in high amounts of heat and mechanical stress, which leads to serious tool wear. The Minimal Quantity Lubrication reduces the frictional condition at the chip-tool, decreases cutting force and cutting temperature, and delays the tool failure.

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