Analytical Model of Progression of Flank Wear Land Width in Drilling

2016 ◽  
Author(s):  
Ranjan Das ◽  
Suhas S. Joshi ◽  
Harish C. Barshilia
Keyword(s):  
Wear Rate ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Limited Attention ◽  
Orthogonal Machining ◽  
Pin On Disc ◽  
Cutting Velocity ◽  
Temperature Dependent Properties ◽  
Land Width

In multi-point operations like drilling, cutting velocities and cutting edge geometries vary along cutting lips so is the rate of progression of flank wear. Analytical evaluation of flank wear land width in the case of complex tools has received a limited attention so far. This work evaluates progression of flank wear in orthogonal machining and adopts it to drilling. An abrasive flank wear has been modeled, wherein, cutting speed determines the rate of abrasion, and the feed rate determines the chip load. The model considers stress distribution along rake surfaces, and temperature dependent properties of tool and work materials. Assuming that the flank wear follows a typical wear progression as in a pin-on-disc test, the model evaluates cutting forces and the consequent abrasive wear rate for an orthogonal cutting. To adopt it to drilling, variation in cutting velocity and, dynamic variation in rake, shear and friction angles along the length of the cutting lips have been considered. Knowing the wear rate, the length of the worn out flank (VB) has been evaluated. The model captures progression of flank wear in zones I, II and III of a typical tool life plot. It marginally underestimates the wear in the rapid wear region and marginally overestimates it in the steady-state region.

Analytical Model of Progression of Flank Wear Land Width in Drilling

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Ranjan Das ◽  
Suhas S. Joshi ◽  
Harish C. Barshilia
Keyword(s):  
Wear Rate ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Limited Attention ◽  
Orthogonal Machining ◽  
Cutting Velocity ◽  
Temperature Dependent Properties ◽  
Pin On Disk ◽  
Land Width

In multipoint operations like drilling, cutting velocities and cutting-edge geometries vary along cutting lips so is the rate of progression of flank wear. Analytical evaluation of flank wear land width in the case of complex tools has received a limited attention so far. This work evaluates progression of flank wear in orthogonal machining and adopts it to drilling. An abrasive flank wear has been modeled, wherein, cutting speed determines the rate of abrasion, and the feed rate determines the chip load. The model considers stress distribution along rake surfaces, and temperature-dependent properties of tool and work materials. Assuming that the flank wear follows a typical wear progression as in a pin-on-disk test, the model evaluates cutting forces and the consequent abrasive wear rate for an orthogonal cutting. To adopt it to drilling, variation in cutting velocity and dynamic variation in rake, shear, and friction angles along the length of the cutting lips have been considered. Knowing the wear rate, the length of the worn-out flank (vb) has been evaluated. The model captures progression of flank wear in zones (i), (ii), and (iii) of a typical tool-life plot. It marginally underestimates the wear in the rapid wear region and marginally overestimates it in the steady-state region.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

scholarly journals Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

2020 ◽  
Vol 5 (2) ◽  
pp. 50-54
Author(s):  
Muataz Al Hazza ◽  
Khadijah Muhammad
Keyword(s):  
Statistical Analysis ◽  
Wear Rate ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis.  JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

Wear mechanisms of TiN-coated CBN tool during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (4) ◽  
pp. 553-566 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Wear Rate ◽  
Feed Rate ◽  
Wear Mechanisms ◽  
High Speed ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Die Steel

The aim of the present investigation was to identify the wear mechanisms of TiN-coated CBN tools prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed were abrasion wear at low cutting speed, low feed rate, and high workpiece hardness; formation of a transferred layer resulting from tribochemical reactions between constituents of the tool and workpiece material at high speed; and the formation of built-up edges at moderate cutting speed. Hard carbide particles of the work material at higher feed rate severely abraded the tool flank land, resulting in shallow grooves due to the detachment of CBN grains. At greater depth of cut, the built-up edges and transferred layer reduced friction and tool wear. Excessive adhesion of workpiece material followed by plastic deformation and notching were clearly visible at low workpiece hardness (47 HRC). The influence of cutting speed, feed rate, depth of cut, and workpiece hardness on the progressive tool flank wear, i.e. flank wear rate (VBr, μm/mm) in the steady wear region, was also analysed. The flank wear rate was observed to decrease with increase in cutting speed, depth of cut, and workpiece hardness, but after an initial decrease it increased with increase in feed rate.

An Experimental Study of Orthogonal Cutting of SiCp/Al Composites: Cutting Forces Analysis

2012 ◽  
Vol 500 ◽  
pp. 230-235
Author(s):  
Shu Tao Huang ◽  
Li Zhou ◽  
Jin Lei Wang
Keyword(s):  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Mechanical And Thermal Properties ◽  
Cutting Depth ◽  
Metal Parts ◽  
Orthogonal Machining ◽  
Rapid Tool

Due to the superior mechanical and thermal properties of SiCp/Al composites, their poor machinability has been the main deterrent to their substitution for metal parts. Machining of SiCp/Al composites has been considerably difficult because the extremely abrasive nature of SiC reinforcements causes rapid tool wear. In this paper, an experiment was carried out to investigate the influence of the cutting speed, cutting depth and tool rake angle on cutting force during orthogonal machining of SiCp/Al composites. The results indicate that the cutting depth is one of the main cutting parameters that affect the cutting force, while the cutting speed and tool rake angle have no significant effects on the cutting force.

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

Experimental and Numerical Investigation into Residual Stress During Turning Operation for Stainless Steel AISI 316

2020 ◽  
Vol 38 (12A) ◽  
pp. 1862-1870
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Main Role ◽  
Turning Operation ◽  
Aisi 316

RS (residual stresses) represent the main role in the performance of structures and machined parts. The main objective of this paper is to investigate the effect of feed rate with constant cutting speed and depth of cut on residual stresses in orthogonal cutting, using Tungsten carbide cutting tools when machining AISI 316 in turning operation. AISI 316 stainless steel was selected in experiments since it is used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, food and beverage industry. Four feed rates were selected (0.228, 0.16, 0.08 and 0.065) mm/rev when cutting speed is constant 71 mm/min and depth of cutting 2 mm. The experimental results of residual stresses were (-15.75, 12.84, 64.9, 37.74) MPa and the numerical results of residual stresses were (-15, 12, 59, and 37) MPa. The best value of residual stresses is (-15.75 and -15) MPa when it is in a compressive way. The results showed that the percentage error between numerical by using (ABAQUS/ CAE ver. 2017) and experimental work measured by X-ray diffraction is range (2-15) %.

scholarly journals Serrated Chips Formation in Micro Orthogonal Cutting of Ti6Al4V Alloys with Equiaxial and Martensitic Microstructures

Micromachines ◽  
2019 ◽  
Vol 10 (3) ◽  
pp. 197 ◽  
Author(s):  
ZeJia Zhao ◽  
Suet To ◽  
ZhuoXuan Zhuang
Keyword(s):  
Cutting Force ◽  
Unit Length ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Orthogonal Machining ◽  
Large Yield ◽  
Power Spectral ◽  
Straight Line ◽  
Serrated Chips ◽  
Electropulsing Treatment

The formation of serrated chips is an important feature during machining of difficult-to-cut materials, such as titanium alloy, nickel based alloy, and some steels. In this study, Ti6Al4V alloys with equiaxial and acicular martensitic microstructures were adopted to analyze the effects of material structures on the formation of serrated chips in straight line micro orthogonal machining. The martensitic alloy was obtained using highly efficient electropulsing treatment (EPT) followed by water quenching. The results showed that serrated chips could be formed on both Ti6Al4V alloys, however the chip features varied with material microstructures. The number of chip segments per unit length of the alloy with martensite was more than that of the equiaxial alloy due to poor ductility. Besides, the average cutting and thrust forces were about 8.41 and 4.53 N, respectively, for the equiaxed Ti6Al4V alloys, which were consistently lower than those with a martensitic structure. The high cutting force of martensitic alloy is because of the large yield stress required to overcome plastic deformation, and this force is also significantly affected by the orientations of the martensite. Power spectral density (PSD) analyses indicated that the characteristic frequency of cutting force variation of the equiaxed alloy ranged from 100 to 200 Hz, while it ranged from 200 to 400 Hz for workpieces with martensites, which was supposedly due to the formation of serrated chips during the machining process.

Identification of Process Damping Coefficient Based on Material Constitutive Property

2014 ◽  
Author(s):  
Xiaoliang Jin
Keyword(s):  
Energy Dissipation ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Machining Process ◽  
Damping Coefficient ◽  
Chatter Stability ◽  
Workpiece Material ◽  
Process Damping ◽  
Constitutive Property

The contact between the tool flank wear land and wavy surface of workpiece causes energy dissipation which influences the tool vibration and chatter stability during a dynamic machining process. The process damping coefficient is affected by cutting conditions and constitutive property of workpiece material. This paper presents a finite element model of dynamic orthogonal cutting process with tool round edge and flank wear land. The process damping coefficient is identified based on the energy dissipation principle. The simulated results are experimentally validated.

Evaluation of changes in mechanical properties of O-ring in one-piece and two-piece ball retained implant-supported overdentures: A three-year retrospective study.

2021 ◽  
Author(s):  
Fathima Banu Raza ◽  
Anand Kumar
Keyword(s):  
Mechanical Properties ◽  
Wear Resistance ◽  
Retrospective Study ◽  
Statistical Analysis ◽  
Wear Rate ◽  
Digital Camera ◽  
Maximum Displacement ◽  
Pin On Disc ◽  
The One ◽  
Insight Into

The o-rings in ball retained overdentures deteriorate with time and need replacement to restore the retentive quality. We evaluated retrospectively the mechanical properties of o-rings after 3 years in function in one and two-piece implant-supported overdentures. The o-rings were retrieved from one-piece (Myriad snap, Equinox-Straumann, 3.3 x 13mm) and two-piece (Neo Biotech, 3.3 x 13mm) implant-supported overdenture patients. A total of 16 pairs of matrices were tested for wear, type of damage and elasticity using Pin on Disc method, USB Digital Camera in 30x zoom and Universal Tensile Machine respectively. The statistical analysis for independent groups were done with the Mann-Whitney U test. Assessment of used O-rings showed 84% more wear in the two-piece system with an abrasive type of damage while 46% wear in the one-piece system with a compressive type of damage. The o-rings in one-piece system showed increase in elongation and maximum displacement to 2% and 7% respectively, while two-piece system showed decrease in elongation and maximum displacement by 13% and 6% respectively. In one-piece system, the loss of retention was more with slow wear rate and in two-piece system, the wear resistance of O-rings decreased due to increased stiffness. Further studies to evaluate the changes in O-ring with increased sample size and at interval 1 year will pave way for insight into the progressive changes in the mechanical properties of an O-ring.

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