Cutting Force and Friction Modelling in High Speed End-Milling

2015 ◽  
Author(s):  
Sunday J. Ojolo ◽  
Olumuwiya Agunsoye ◽  
Oluwole Adesina ◽  
Gbeminiyi M. Sobamowo
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece

Temperature field in metal cutting process is one of the most important phenomena in machining process. Temperature rise in machining directly or indirectly determines other cutting parameters such as tool life, tool wear, thermal deformation, surface quality and mechanics of chip formation. The variation in temperature of a cutting tool in end milling is more complicated than any other machining operation especially in high speed machining. It is therefore very important to investigate the temperature distribution on the cutting tool–work piece interface in end milling operation. The determination of the temperature field is carried out by the analysis of heat transfer in metal cutting zone. Most studies previously carried out on the temperature distribution model analysis were based on analytical model and with the used of conventional machining that is continuous cutting in nature. The limitations discovered in the models and validated experiments include the oversimplified assumptions which affect the accuracy of the models. In metal cutting process, thermo-mechanical coupling is required and to carry out any temperature field determination successfully, there is need to address the issue of various forces acting during cutting and the frictional effect on the tool-work piece interface. Most previous studies on the temperature field either neglected the effect of friction or assumed it to be constant. The friction model at the tool-work interface and tool-chip interface in metal cutting play a vital role in influencing the modelling process and the accuracy of predicted cutting forces, stress, and temperature distribution. In this work, mechanistic model was adopted to establish the cutting forces and also a new coefficient of friction was also established. This can be used to simulate the cutting process in order to enhance the machining quality especially surface finish and monitor the wear of tool.

Basic Mechanics of the Metal-Cutting Process

1944 ◽  
Vol 11 (3) ◽  
pp. A168-A175 ◽  
Author(s):  
M. Eugene Merchant
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Work Piece ◽  
Machining Operations ◽  
Work Done ◽  
Metal Work

Abstract The author presents a mathematical analysis of the geometry and mechanics of the metal-cutting process, covering two common types of geometry which occur in cutting. This analysis offers a key for the study of engineering problems in the field of metal cutting in terms of such fundamental quantities as strain, rate of shear, friction between chip and tool, shear strength of the metal, work done in shearing the metal and in overcoming friction, etc. The two cases covered are, in essence, that of a straight-edged cutting tool moving relative to the work-piece in a direction perpendicular to its cutting edge, termed “orthogonal cutting,” and that of a similar cutting tool so set that the cutting edge is oblique to the direction of relative motion of tool and work, termed “oblique cutting.” Equations are developed which permit the calculation of such quantities as those just enumerated from readily observable values. The theoretical findings are particularly applicable and significant in the case of present-day high-speed machining operations with sintered-carbide tools.

Finite Element Analysis of High Speed Cutting Tool

2012 ◽  
Vol 268-270 ◽  
pp. 496-499 ◽  
Author(s):  
Wei Fan ◽  
Xin Liu
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Tool Geometry ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Finite Element Software

The cutting principle of high speed machining is analyzed, and the key technology of building high speed cutting finite element simulation model is systemic explained. By simplifying high speed cutting process, using the fastest solution of nonlinear finite element software ADINA which is development in recent years to establish the three dimensional finite element model of high speed metal cutting, and to predict the cutting force of different cutting tool geometry parameter combination of high speed cutting process, the high speed cutting processing cutting tool analysis and processing parameter optimization analysis method are put forwarded, so as to provide a new tool for the research of high speed machining process and provide basis for the cutting tool choice during high-speed nc cutting process.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

An Integral Method to Determine Workpiece Flow Stress and Friction Characteristics in Metal Cutting

2015 ◽  
Vol 9 (6) ◽  
pp. 775-781
Author(s):  
Norfariza Wahab ◽  
◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo-Young Kim ◽  
...  
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Machining Parameters ◽  
Friction Characteristics ◽  
High Speed Cutting

In recent times, numerical simulation techniques have been commonly used to estimate and predict machining parameters such as cutting forces, stresses, and temperature distribution. However, it is very difficult to estimate the flow stress of a workpiece and the friction characteristics at a tool/chip interface, particularly during a high-speed cutting process. The objective of this study is to improve the accuracy of the present method and simultaneously determine the characteristics of the flow stress of a workpiece and friction at the cutting edge under a high strain rate and temperature during the cutting process. In this study, the Johnson-Cook (JC) flow stress model is used as a function of strain, strain rate, and temperature. The friction characteristic was estimated by minimizing the difference between the predicted and measured results of principal force, thrust force, and shear angle. The shear friction equation was used to estimate the friction characteristics. Therefore, by comparing the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and friction characteristics at the cutting edge during a high-speed cutting process was estimated.

scholarly journals Pengaruh Parameter Pemesinan terhadap Kualitas Hasil Potong Mesin Bubut Maximat V13 pada Benda Kerja Poros PVC

2019 ◽  
Vol 2 (02) ◽  
pp. 19-24
Author(s):  
Kasijanto Kasijanto ◽  
Sadar Wahjudi ◽  
Listiyono Listiyono ◽  
Muhammad Fakhruddin
Keyword(s):  
Metal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece ◽  
Machining Processes ◽  
Cutting Surface ◽  
Spindle Rotation ◽  
Feeding Speed ◽  
Tool Types

Metal cutting process (cutting process) is to cut metal to get the shape and size and quality of the planned cutting surface. The metal cutting process is carried out with special tools, according to the type of cutting process. So the tools for one process cannot be used in another process, even for similar processes, the tools cannot be exchanged if the cutting plans are not the same. Lathe process is a machining process to produce cylindrical machine parts which are carried out using a Lathe. Its basic form can be defined as the machining process of the outer surface of cylindrical or flat lathe objects. Polyvinyl Chloride, commonly abbreviated as PVC, is the third-order thermoplastic polymer in terms of total usage in the world, after Polyethylene (PE) and Polypropylene (PP). Worldwide, more than 50% of PVC produced is used in construction. PVC is produced by polymerizing vinyl chloride monomers (CH2 = CHCl). Because 57% of its mass is chlorine, PVC is the polymer that uses the lowest petroleum feedstock among other polymers. This research follows up the selection of configuration of the lathe machining process using plastic work pieces. In this study, Maximat V13 lathe and PVC type plastic were used. The variation of machining processes are spindle rotation (320, 540, and 900 rpm), feeding speed (0.07, 0.14, and 0.28), the use of tool types (carbide and HSS) and cooling (without cooling, coolant, and oil). So, with this research, it is expected that the optimal parameters in determining the configuration of the lathe machining process on a PVC work piece to produce a good turning surface can be achieved  

scholarly journals Strain Rate of Metal Deformation in the Machining Process from a Fluid Flow Perspective

2020 ◽  
Vol 10 (9) ◽  
pp. 3057
Author(s):  
Keguo Zhang ◽  
Keyi Wang ◽  
Zhanqiang Liu ◽  
Xiaodong Xu
Keyword(s):  
Fluid Flow ◽  
Strain Rate ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Shear Plane ◽  
Cutting Process ◽  
Machining Process ◽  
Rake Face ◽  
Metal Deformation

Metal cutting speeds are getting faster with the development of high-speed cutting technology, and with the increase in cutting speed, the strain rate will become larger, which makes the study of the metal cutting process more inconvenient. At the same time, with the increase in strain rate, the dislocation movement controlling the plastic deformation mechanism of metal will change from thermal activation to a damping mechanism, which makes the metal deformation behave more like a fluid. Therefore, it is necessary to explore new ways of studying machining from the perspective of fluid flow. Based on this, a fluid model of the metal cutting process is established, and a method for calculating the strain rate is proposed from the point of view of flow. The results of the simulation and measurements are compared and analyzed. The results show that the strain rate on the rake face will be affected by the friction between the chip and tool; the nearer the distance between the chip layer and tool rake face, the bigger the strain rate will be. The strain rate in the central shear plane is much larger than in other areas along the shear plane direction, and in which two ends are the biggest. It can achieve rougher, quantitative research. This shows it is feasible to study machining from the viewpoint of fluid flow, though it still needs a lot of theoretical support and experimental confirmation.

Machining Characteristics of Leaded Steel

1960 ◽  
Vol 82 (2) ◽  
pp. 347-359 ◽  
Author(s):  
Fenton L. Bagley ◽  
Roy Mennell
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Work Piece ◽  
Two Dimensional ◽  
Life Data ◽  
Wide Range ◽  
Machining Characteristics ◽  
Lead Addition ◽  
Cutting Speeds

The effects of lead addition in alloy steel upon the metal-cutting process were explored over a wide range of conditions. In particular, a range of cutting speeds (from 50 to 800 fpm) and workpiece hardness (from 230 to 450 Bhn) were investigated on one work-piece material (4340) using principally a carbide (C-6) cutting tool. Orthogonal (two-dimensional) data was taken to describe the metal-cutting process, and tool-life data were obtained by running a typical production tool to failure at the various cutting conditions. Several mechanisms to explain experimental results, including lead acting as a lubricant, are discussed.

Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes

2011 ◽  
Vol 223 ◽  
pp. 85-92 ◽  
Author(s):  
Balázs Tukora ◽  
Tibor Szalay
Keyword(s):  
Cutting Force ◽  
Real Time ◽  
Cutting Forces ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Work Piece ◽  
Processing Unit ◽  
Cutting Force Prediction ◽  
Force Prediction

In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

Orthogonal Variable Thickness Cutting Modeling of Surface Milling and Physical Fields Simulation

2016 ◽  
Vol 836-837 ◽  
pp. 468-475
Author(s):  
Wei Zhang ◽  
Chang Jian Du ◽  
Xiao Liang Cheng ◽  
Feng Shun He
Keyword(s):  
Temperature Field ◽  
Variable Thickness ◽  
High Speed ◽  
End Milling ◽  
Three Dimensional ◽  
Complex Surface ◽  
Work Piece ◽  
Ball End Milling ◽  
Physical Fields ◽  
Cutting Model

When milling the complex surface with the ball-end milling cutter, the cutting thickness always changes in ball-end milling process. At present, many milling models are actually simplified with unchanged cutting thickness, which ignores the ball-end milling cutting with complex tool-work piece relationship. According to the characteristics of the ball-end milling, orthogonal variable thickness cutting model is established based on the study of three-dimensional contact relationship of tool-work piece. The simulation of the stress field and the temperature field in hardened steel Cr12MoV orthogonal variable thickness cutting process is conducted, and comparative analysis of stress and temperature field distribution of high-speed milling and conventional milling is made. The cutting model of orthogonal variable thickness cutting can reflect the characteristics of surface milling accurately, which can be further used in the study of changing characteristics of physical fields and the optimization of cutting and tool parameters to improve the machining efficiency and quality.

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