Specific Material Removal Rate Calculation in Five-Axis Grinding

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Raja Kountanya ◽  
Changsheng Guo
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Tool Path ◽  
Removal Rate ◽  
Unit Length ◽  
Chip Thickness ◽  
Impeller Blade ◽  
Tool Profile ◽  
Specific Material ◽  
Five Axis

Specific material removal rate (MRR) q′ was calculated for five-axis grinding in a virtual machining simulation environment (VMSE). The axis-symmetric tool rotational profile was arc-length parameterized. The twisted grazing curve due to the concurrent translation and rotation in every move was modeled through an exact velocity field and areal MRR density q″, positive in the front of the grazing curve on the tool surface. Variation of q′ and equivalent chip thickness h within the instantaneous engagement contour were deduced from q″. Illustrative results with a five-axis impeller blade finishing simulation are shown. The results were benchmarked against an average q′ calculated from the instantaneous MRR from the VMSE. As a function of time, maximum chip thickness hmax within the extents of contact along the tool profile in every move showed more isolated peaks than corresponding qmax′. Maximum cumulative material removed per unit length Qmax′ along the tool profile from all the moves was calculated to predict axial location of maximum risk of cutter degradation.  Qmax′ and hmax are useful metrics for tool path diagnosis and tool wear analysis.

In Vitro Dental Cutting of Feldspar and Leucite Glass Ceramics Using an Electric Handpiece

2012 ◽  
Author(s):  
Xiao-Fei Song ◽  
Jianhui Peng ◽  
Ling Yin ◽  
Bin Lin
Keyword(s):  
Material Removal Rate ◽  
Glass Ceramic ◽  
Material Removal ◽  
Removal Rate ◽  
Chip Thickness ◽  
Glass Ceramics ◽  
Undeformed Chip Thickness ◽  
Normal Forces ◽  
Specific Material ◽  
Abrasive Cutting

Glass ceramics are important restorative materials in dentistry. They are used as veneer-core bilayer all-ceramic or metal-fused ceramic restorations or monolithic inlays/onlays/crowns to replace missing or damaged tooth structures for aesthetic and functional purposes. However, glass ceramic materials, such as feldspar and leucite glass ceramics, which are subject to this investigation, are brittle and easily induced microfractures in abrasive cutting using dental handpieces and coarse burs. In this paper, we investigated the dental abrasive cutting characteristics of feldspar and leucite glass ceramics using a high-speed electric handpiece and coarse diamond burs. Cutting forces, specific removal energy, surface roughness and morphology were investigated as functions of specific material removal rate and maximum undeformed chip thickness. The results indicate that increasing the specific material removal rate or the maximum undeformed chip thickness resulted in increases in both tangential and normal forces, but a decrease in specific removal energy for both ceramics. Tangential, normal forces and specific removal energy were significantly larger in up cutting than those in down cutting. Surface roughness for the two ceramics was not affected by the specific removal rate or the maximum undeformed chip thickness. Both microfrature and ductile microcutting morphology were observed in the machined surfaces for both ceramics. There existed a brittle to ductile transition trend when decreasing the specific material removal rate or the maximum undeformed chip thickness for the two ceramics. In comparison with feldspar glass ceramic, leucite glass ceramic generated better surfaces due to its more ductile deformation occurring in dental cutting.

Optimization of Nickel Alloy Turning Considering the Tool in Different Wear Phases

2017 ◽  
Vol 261 ◽  
pp. 243-250
Author(s):  
Wojciech Zębala
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Tool Path ◽  
Removal Rate ◽  
Aircraft Engine ◽  
Material Model ◽  
Turning Process ◽  
Engine Part ◽  
Nickel Based Alloy

Paper presents some turning process optimization investigations, concerning modeling of tool wear when turning a difficult-to-cut material like nickel based alloy. The workpiece was an aircraft engine part in the form of disc. The aim of the research was an optimization of the cutting data (feed rate) for the purpose to improve the cutting process (stabilization of the cutting force course along the tool path) and increase the material removal rate (efficiency of the machining). A “force material model”, based on the tool behavior in its different wear phases was established.

Burn threshold of high-carbon steel in high-efficiency deep grinding

2002 ◽  
Vol 216 (3) ◽  
pp. 357-364 ◽  
Author(s):  
T Jin ◽  
D J Stephenson ◽  
J Corbett
Keyword(s):  
Carbon Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
High Carbon Steel ◽  
Numerical Control ◽  
Theoretical Expression ◽  
High Carbon ◽  
Five Axis

The burn-threshold of high-carbon steel (51CrV4) in the high-efficiency deep-grinding (HEDG) process is investigated. It is found that the burn threshold in HEDG is determined by the wheel-workpiece contact length, material removal rate and wheel speed. A theoretical expression for the burn threshold has been derived, which is based on the thermal modelling for deep grinding and takes account of the grinding parameters, wheel conditions, thermal properties of the workpiece and abrasive grain, and the heat convected away by the coolant and chips. The predicted upper and lower boundaries for occurrence of workpiece burn show good agreements with the experimental observations. It is shown that burn threshold in HEDG is related to the film boiling of process coolant and the critical heat flux increases as the specific material removal rate increases. The experiments were carried out on an Edgetek five-axis computer numerical control (CNC) grinding machine, which is capable of HEDG in a relatively wide range of process parameters.

Optimizing of Integral Impeller NC Program Based on the Material Removal Rate

2014 ◽  
Vol 1030-1032 ◽  
pp. 1305-1308
Author(s):  
Shi Chao Li ◽  
Song Lin Wu ◽  
Yan Kun Liang
Keyword(s):  
Material Removal Rate ◽  
Machine Tools ◽  
Material Removal ◽  
Removal Rate ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Five Axis

It is a general processing technology that multi-axis NC machine tools is used for machining impeller at present. In order to improve the machining accuracy of the five-axis NC machine tools, the paper analyzes the computing interpolation error of the Multi-axis CNC system in detail. Some of the measures of tools selection have been proposed in purpose of diminishing the accumulative error of the system. The paper also establishes the optimized objective function to optimize the process parameters of the CNC machining based on the material removal rate. All these measures will improve the machining efficiency significantly and increase the stationary of the machining process.

Influence Of Tool Motions On Chip Thickness And Material Removal Rate

2006 ◽  
Vol 21 (4) ◽  
pp. 237-239
Author(s):  
L. Saï ◽  
W. Bouzid ◽  
A. Zghal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Chip Thickness ◽  
On Chip

Particularities of Grinding High Speed Steel Punching Tools

2011 ◽  
Vol 325 ◽  
pp. 177-182 ◽  
Author(s):  
Peter Krajnik ◽  
Radovan Drazumeric ◽  
Jeffrey Badger ◽  
Janez Kopač ◽  
Cornel Mihai Nicolescu
Keyword(s):  
Simulation Model ◽  
Material Removal Rate ◽  
Temperature Rise ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Maximum Temperature ◽  
Specific Grinding Energy ◽  
Specific Material

A simulation model of a punch grinding process has been used to determine optimal parameters to reduce grinding cycle time and achieve a constant-temperature no-burn situation. Two basic outputs of the simulation model include arc length of contact and specific material removal rate that are both time-variant. A thermal model is included in the simulation to calculate maximum grinding temperature rise. The simulation-based optimization can help to avoid thermal damage, which includes thermal softening, residual tensile stress, and rehardening burn. The grindability of high speed steel (HSS) is presented in terms of specific grinding energy versus undeformed chip thickness and maximum temperature rise versus specific material removal rate. It is shown that for a given specific material removal rate lower temperatures are achieved when grinding fast and shallow. Higher temperatures, characteristic for slow and deep grinding, soften the material leading to a lower specific grinding energy, especially if grinding is timid. Lowest values of specific grinding energy can be achieved in fast and shallow grinding at aggressive grinding conditions.

scholarly journals Influence of the Anode Material and the Flushing Gas on the Dry Electrical Discharge Machining Process

2013 ◽  
Vol 7 (5) ◽  
pp. 581-592
Author(s):  
Raoul Roth ◽  
◽  
Beck Lukas ◽  
Hartmi Balzer ◽  
Friedrich Kuster ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Work Piece ◽  
Specific Material ◽  
Environmentally Friendly Process ◽  
Dry Electrical Discharge Machining

In the last years dry electrical discharge machining (DEDM) has been proposed as an alternative to the traditional EDM. The main reason for these efforts is the absence of a liquid dielectric which results in a simpler and environmentally friendly process. This paper presents measurements of the material removal rate in function of different tool electrodes, work piece materials and flushing gases put in relation with the breakdown behavior of the process. Evaluation of absolute and current specific material removal rate are presented. The data show a big influence on the material removal rate depending on the combination of work piece material and flushing gas. Two different effects are observed, the first enhancing the removal per spark and the second one reducing the short circuiting occurrence. The share of these two effects on the enhancing of the absolute material removal rate also differs in function of the work piece material. It is suggested that the chemical reaction strongly influences the process in two different ways, on one hand releasing a surplus of energy and on the other hand changing the debris particles’ properties.

Sign in / Sign up

Export Citation Format

Share Document