Numerical Analysis of Cutting With Chamfered and Worn Edge Tools

2000 ◽  
Author(s):  
Mohammad-R. Movahhedy ◽  
Yusuf Altintas ◽  
Mohamed S. Gadala
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Hard Materials ◽  
Ale Finite Element Method ◽  
Diffusion Wear ◽  
Dead Material ◽  
Chip Removal

Abstract In high-speed machining of hard materials, tools with chamfered edges and tool materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide or CBN tools. The analysis is based on the use of arbitrary Lagrangian-Eulerian (ALE) finite element method, which makes it possible to analyze the cutting action without having to resort to node separation methods or remeshing. Simulations include cutting with tools of different chamfer angles at a range of cutting speeds and the numerical results are compared with experimental data obtained under similar cutting conditions. The study shows that a region of dead material zone is formed under the chamfer and acts as the effective cutting edge of the tool (in accordance with experimental observations). As a result, the chip formation process is not significantly affected by the presence of the chamfer. However, the forces, the thrust force in particular, are considerably increased. The effect of cutting speed on the process is also studied and is shown to produce a significant increase in maximum temperature on the rake face.

Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools

2002 ◽  
Vol 124 (2) ◽  
pp. 178-188 ◽  
Author(s):  
M. R. Movahhedy, ◽  
Y. Altintas, ◽  
M. S. Gadala,
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Hard Materials ◽  
Ale Finite Element Method ◽  
Diffusion Wear ◽  
Process Simulations

In high speed machining of hard materials, tools with chamfered edge and materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide and CBN tools. The analysis is based on the use of ALE finite element method for continuous chip formation process. Simulations include cutting with tools of different chamfer angles and cutting speeds. The study shows that a region of trapped material zone is formed under the chamfer and acts as the effective cutting edge of the tool, in accordance with experimental observations. While the chip formation process is not significantly affected by the presence of the chamfer, the cutting forces are increased. The effect of cutting speed on the process is also studied.

Experiment of Temperature Field for High Speed Orthogonal Turning

2011 ◽  
Vol 117-119 ◽  
pp. 594-597 ◽  
Author(s):  
Mu Lan Wang ◽  
Yong Feng ◽  
Xiao Xia Li ◽  
Bao Sheng Wang
Keyword(s):  
Temperature Field ◽  
High Speed ◽  
Model Simulation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental System ◽  
Maximum Temperature ◽  
Fem Model ◽  
High Speed Cutting ◽  
Orthogonal Turning

An experimental system used for temperature measurement is designed by the K-type thermocouple thermometry to achieve a direct measurement of cutting temperature in high speed orthogonal turning. The general regularity of temperature distribution is concluded, and the corresponding influences of cutting speed and cutting depth on the maximum temperature value are discussed in detail. Experimental data and simulating results are comparative analyzed to demonstrate the feasibility and correctness of Finite Element Method (FEM) model simulation and analytical solution. The verified model of temperature field can be applied to develop an effective non-contact soft-sensing method for high speed cutting temperature.

scholarly journals Temperature Measurement by Visible Pyrometry: Orthogonal Cutting Application

2004 ◽  
Vol 126 (6) ◽  
pp. 931-936 ◽  
Author(s):  
N. Ranc ◽  
V. Pina ◽  
G. Sutter ◽  
S. Philippon
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Broad Band ◽  
Cutting Speed ◽  
Low Carbon Steel ◽  
Ccd Camera ◽  
Maximum Temperature ◽  
Low Carbon ◽  
Observation Area ◽  
Good Spatial Resolution

The working processes of metallic materials at high strain rate like forging, stamping and machining often induce high temperatures that are difficult to quantify precisely. In this work we, developed a high-speed broad band visible pyrometer using an intensified CCD camera (spectral range: 0.4 μm–0.9 μm). The advantage of the visible pyrometry technique is to limit the temperature error due to the uncertainties on the emissivity value and to have a good spatial resolution (3.6 μm) and a large observation area. This pyrometer was validated in the case of high speed machining and more precisely in the orthogonal cutting of a low carbon steel XC18. The cutting speed varies between 22 ms−1 and 60 ms−1. The experimental device allows one to visualize the evolution of the temperature field in the chip according to the cutting speed. The maximum temperature in the chip can reach 730°C and minimal temperature which can be detected is around 550°C.

Effect of Cutting Speed on Wear Property of TiAlN PVD Coated Tools in High-Speed Milling of AISI P20 Mold Steel

2014 ◽  
Vol 621 ◽  
pp. 75-81 ◽  
Author(s):  
You Xi Lin ◽  
Hua Lin ◽  
Zhen Wei Han
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Wear Property ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
High Speeds ◽  
Coated Tools ◽  
Diffusion Wear ◽  
Aisi P20 ◽  
Important Means

High speed cutting is an important means to improve the efficiency and the quality of machining mold steel, but the tool wear is one of the key factors restricting the increase of the cutting speed, leading to higher requirements for cutting tool materials. At present the researches of high-speed cutting of mold steel are mainly on the hardness mold steel, but less on P20 mold steel which hardness is 30-42HRC. This paper mainly studies the effect of cutting speed on wear property of TiAlN PVD coated tools when high-speed milling of P20 mold steels. The experiment was conducted using two different high cutting speeds under dry condition, 320m/min and 500m/min. Wear characterization of the rake and the flank surfaces as well as the collected chips were performed using scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX). It was found that at high speeds, the dominant wear mechanisms were oxidation wear and diffusion wear, followed by adhesive wear and melt wear; as the cutting speed increased, the wear surface area of rake face will be closer to the main cutting edge.

MAXITE

Alloy Digest ◽  
1986 ◽  
Vol 35 (7) ◽  
Keyword(s):  
Tool Steel ◽  
High Speed ◽  
Single Point ◽  
Cutting Tools ◽  
Heat Treating ◽  
Steel Company ◽  
Hardened Alloy ◽  
Hard Materials ◽  
Alloy Steels ◽  
Chip Removal

Abstract MAXITE is a tungsten-cobalt-vanadium high-speed tool steel. It is best used when maximum chip removal with single-point cutting tools is of primary importance. Tools made from Maxite will cut tough and hard materials such as stainless steels and hardened alloy steels with relative ease. It is excellent for cutting weld flashings and gritty, scaly hard castings. Among its many applications are drills, lathe tools, planer tools, cutoff tools and roll-turning tools. This datasheet provides information on composition and hardness. It also includes information on wear resistance as well as forming, heat treating, and machining. Filing Code: TS-461. Producer or source: Columbia Tool Steel Company.

Linear Sawing Apparatus and its Evaluation for Research Into High Speed Bone Sawing

2011 ◽  
Author(s):  
John J. Pearlman ◽  
Anil Saigal ◽  
Thomas P. James
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Material Behavior ◽  
Depth Of Cut ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Saw Blade

Previous research into the cutting mechanics of bone sawing has been primarily approached from the perspective of orthogonal metal machining with a single edge cutting tool. This was a natural progression from the larger body of knowledge on the mechanics of metal cutting. However, there are significant differences between typical orthogonal metal cutting parameters and those encountered in bone sawing, such as anisotropic material behavior, depth of cut on the order of cutting edge radius, chip formation mechanism in the context of a saw blade kerf, non-orthogonal considerations of set saw blade teeth, and cutting speed to name a few. In the present study, an attempt is made to overcome these shortcomings by employing a unique sawing fixture, developed to establish cutting speeds equivalent to those of typical sagittal saws used in orthopaedic procedures. The apparatus was developed for research into bone sawing mechanics and is not intended to be a commercial sawing machine. The sawing fixture incorporates the cutting speed possible with lathe operations, as well as the linear cutting capabilities of a milling machine. Depths of cut are on the same order of magnitude as the cutting edge radius typical to saw blade teeth. Initial measurements of cutting and thrust force, obtained with this new experimental equipment, are compared to previous work.

Tool Face Temperatures in High Speed Milling

1990 ◽  
Vol 112 (2) ◽  
pp. 132-135 ◽  
Author(s):  
P. Lezanski ◽  
M. C. Shaw
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Equilibrium Temperature ◽  
Face Milling ◽  
Maximum Temperature ◽  
Tool Temperature ◽  
Maximum Value ◽  
Exit Temperature ◽  
Intermittent Cutting ◽  
Continuous Chip

While it is now generally understood that in continuous chip forming processes such as turning, there is no magic high speed above which tool temperature decreases and tool life increases with increased cutting speed. However, it has been suggested that this may not be the case in intermittent cutting operations such as face milling. It is argued that in such an operation, the tool temperature oscillates between an ambient value at the beginning of a cut and a maximum value at the end of a cut. As cutting speed is increased, the cutting time per cut will decrease and hence the fractional approach to the equilibrium value. Thus, even though the equilibrium temperature will increase with cutting speed, it is conceivable that the maximum temperature at the end of a cut will decrease. This possibility has been tested experimentally using the chip-tool thermocouple technique to record temperature vs time curves for a variety of cutting conditions. In no case was the exit temperature found to decrease with increase in cutting speed.

Tool Wear of PVD Coated Carbide Tool when Finish Turning Inconel 718 under High Speed Machining

2010 ◽  
Vol 129-131 ◽  
pp. 1004-1008 ◽  
Author(s):  
M.Z.A. Yazid ◽  
C.H. Che Hassan ◽  
A.G. Jaharah ◽  
A.I. Gusri ◽  
M.S. Ahmad Yasir
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Nose Radius ◽  
Machining Processes ◽  
Finish Turning ◽  
Diffusion Wear ◽  
Flank Face ◽  
Coated Carbide

This paper reports the results of an experimental works, where Inconel 718, a highly corrosive resistant, nickel-based super alloy, was finish-turning under high speed conditions. The machining processes were carried out at three different cutting conditions (DRY, MQL 50 ml/h and MQL 100 ml/h), three levels of cutting speed (Vc=90, 120 and 150 m/min), two levels of feed rate (f=0.10 and 0.15 mm/rev) and two levels of cutting depth (d=0.30 and 0.50 mm). The tool wear and flank wear progression were monitored, measured and recorded progressively at various time intervals. The experiments indicated that MQL condition performs better than dry condition in term of tool life. Most of the tool failures during machining were due to gradual failure where abrasive and notching wear on the flank face was the dominant followed by, fracture on the flank edge and nose radius. Tool failure due to crater wear was not significant. Wear mechanism such as abrasive and adhesion were observed on the flank face and diffusion wear was observed on the rake face.

Study on the Wear Mechanism of PCD Tools in High-Speed Milling of Al-Si Alloy

2011 ◽  
Vol 381 ◽  
pp. 16-19 ◽  
Author(s):  
Yong Guo Wang ◽  
Biao Liu ◽  
Jiong Yi Song ◽  
Xiang Ping Yan ◽  
Kang Mei Wu
Keyword(s):  
Wear Mechanism ◽  
High Speed ◽  
Energy Dispersive Spectrometer ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Diffusion Wear ◽  
Milling Tool ◽  
Pcd Tools ◽  
And Diffusion

Polycrystalline diamond (PCD) tools have been obtained increasing application in aluminum alloy processing industry due to the excellent surface finish and tool life comparing with other traditional tools. Investigation of the wear mechanism of PCD milling tool for machining Al-Si alloy at cutting speed of 5000m/min (n=12732r/min) has been performed. The wear morphology of tool has been studied by scanning electron microscopy (SEM) and energy dispersive spectrometer (EDS). Results show that PCD milling tool suffers from abrasive wear and diffusion wear on the flank face and adhesive wear on the rake face in the machining process.

FE Analysis of the Effects of Cutting Speed on Thermomechanical Responses of AISI 4142 Steel in High Speed Cutting

2010 ◽  
Vol 97-101 ◽  
pp. 3183-3186
Author(s):  
C.Y. Gao ◽  
B. Fang
Keyword(s):  
Residual Stress ◽  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Maximum Temperature ◽  
State Variables ◽  
Fe Method ◽  
Surface Machining ◽  
High Speed Cutting

The high-speed metal cutting process is analyzed by finite element (FE) method in order to understand the effects of the cutting speed on the thermomechanical responses of workpiece materials. The reliability of numerical simulation is firstly validated by comparing the simulated cutting force with experimental data. Then a series of FE simulations are carried out to reveal the effects of the cutting speed on three key cutting state variables. The cutting force varies with the cutting speed and shows a minimum inflexion at 10 m/s. The maximum temperature in the secondary deformation zone increases gradually with the cutting speed and finally tends to a steady value. The residual stress decreases with the cutting speed as a whole. Thus high speed cutting can improve surface machining precision of product. Besides, it is found that the high residual stress mainly concentrates in the topmost surface layer with a depth of 0.1 mm and sharply decreases to a low level beyond the layer.

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