A Study of the Normal and Shear Stresses on a Cutting Tool

1966 ◽  
Vol 88 (1) ◽  
pp. 51-61 ◽  
Author(s):  
T. C. Hsu
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Contact Length ◽  
Depth Of Cut ◽  
Shear Stresses ◽  
Simple Manner ◽  
Tool Edge ◽  
The Coefficient Of Friction ◽  
Tangential Forces ◽  
Normal And Shear Stresses

This paper contains an explanation for the variation of the “coefficient of friction” in metal cutting. The chip partly sticks to and partly slides over the tool and only in the latter region can friction occur. In the experiments, the contact area between the chip and the tool is controlled and the change in the size of the sticking region is observed. The ploughing force acting on the tool edge is taken into account and the force acting on the tool face is determined. It is found that the force on the tool face varies with the depth of cut and the contact length in a simple manner. From the variation of the normal and tangential forces the stress distribution on the tool face is deduced.

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.

Stress Distribution in a Wedge for Boundary Conditions Approximating to the Rake-Face Loads on a Metal Cutting Tool

1973 ◽  
Vol 15 (3) ◽  
pp. 200-209 ◽  
Author(s):  
P. F. Thomason
Keyword(s):  
Stress Distribution ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Contact Length ◽  
Rake Face ◽  
Line Field ◽  
Tangential Stresses ◽  
Detailed Assessment ◽  
Metal Cutting Tool ◽  
Infinite Wedge

An analysis of published experimental and theoretical slip-line field results for the metal cutting process suggests that, when the tool and workpiece are of high elastic modulus, a reasonable first approximation to the rake-face loading will consist of uniformly distributed normal and tangential stresses over the contact length. An indication of the form of the stress distribution at the tip of a cutting tool is therefore obtained from an isothermal–elastic solution for a two-dimensional infinite wedge, loaded antisymmetrically by uniform normal and tangential stresses adjacent to the apex. Only a preliminary assessment of the results is made, in relation to cutting tool wear and fracture problems, since a more detailed assessment will await a complete thermoelastic solution to the problem.

Mechanical and Thermal Stresses in Clamped, Brazed, and Bonded Carbide Tools

1992 ◽  
Vol 114 (4) ◽  
pp. 377-385 ◽  
Author(s):  
M. A. Younis
Keyword(s):  
Temperature Gradient ◽  
Metal Cutting ◽  
Thermal Stresses ◽  
Rupture Strength ◽  
Shear Stresses ◽  
Flow Strength ◽  
Compressive Stresses ◽  
Bond Layer ◽  
Tool Edge ◽  
Carbide Insert

A model based on the finite element method is presented for determining of thermal and mechanical stresses in a carbide insert due to heat and cutting forces induced during metal cutting with a brazed, clamped, and bonded carbide insert. Analysis revealed a high temperature gradient in the brazed insert, thus causing high thermal stresses. For the bonded insert a low temperature gradient but high temperatures were found, leading to possible tool edge chipping and a significant reduction of the bond layer strength. Finally local maxima of tensile and compressive stresses were identified on the rake face just after the chip had lost contact with the tool face. The estimated tensile stresses were close to the transverse rupture strength of sintered carbide. Shear stresses were at a maximum close to the tool edge at levels nearly equal to the shear flow strength of carbides. High compressive stresses can produce chipping at the tool tip.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

scholarly journals Influences of TiAlN Coating on Cutting Temperature during Orthogonal Machining H13 Hardened Steel

Coatings ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 355 ◽  
Author(s):  
Guangchao Hao ◽  
Zhanqiang Liu ◽  
Xiaoliang Liang ◽  
Jinfu Zhao
Keyword(s):  
Cutting Tool ◽  
Cutting Temperature ◽  
Contact Length ◽  
Hardened Steel ◽  
Tialn Coating ◽  
Orthogonal Machining ◽  
Coated Tools ◽  
Cutting Heat ◽  
Coated Tool ◽  
The Coefficient Of Friction

TiAlN has been widely used in cutting tool coating due to its excellent mechanical and thermal performances. However, the research on the TiAlN coating effect on cutting temperature is not comprehensive enough. In this paper, the friction tests at elevated temperature and hard machining H13 hardened steel tests are conducted by using TiAlN coated tools and uncoated tools, respectively. The results of using TiAlN coated tools are compared with those from using uncoated tools. It is found that the coefficient of friction (COF) between TiAlN coated tool and H13 hardened steel is reduced to 0.63 at 800 °C. The COF value is 0.75 for uncoated tool. Under the same cutting conditions, the TiAlN coating shortens tool-chip contact length. The tangential cutting forces and cutting zone temperatures are decreased with smaller COF and shorter tool-chip contact length. Due to the lower thermal conductivities of TiAlN coating and the Al2O3 oxide layer formatted at tool rake face, the cutting heat conducted into cutting tool substrate was reduced. The cutting temperatures in TiAlN coated tool substrate are decreased by at least 10.68% in this study. The TiAlN coating reduces the cutting temperature by decreasing the cutting heat generation and conduction.

Grey-Based Taguchi Analysis for Optimization of Multi-Objective Machining Process in Turning

2013 ◽  
Vol 4 (2) ◽  
pp. 79-95 ◽  
Author(s):  
Nirmal S. Kalsi ◽  
Rakesh Sehgal ◽  
Vishal S. Sharma
Keyword(s):  
Feed Rate ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Analysis Technique ◽  
Grey Relation

In the present experimental study, Taguchi method and the GRA (grey relation analysis) technique were 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 was selected to analyze the effect of cutting speed, feed rate and depth of cut using cryogenically treated and untreated inserts. The performance was 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 study indicated that 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 turning process. It is concluded that cryogenic treated cutting tool inserts performed better. However, the feed rate affected the process performance most significantly.

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