Development of Smart Tooling Concepts Applied to Ultra-Precision and High Speed Machining

2016 ◽  
Author(s):  
Chao Wang ◽  
Kai Cheng ◽  
Richard Rakowski
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Feedback Signal ◽  
High Speed Machining ◽  
High Speed Drilling ◽  
Ultra Precision ◽  
Smart Machining ◽  
Spindle Development

This paper presents smart tooling concepts applied to ultra-precision and high speed machining, particularly through the development of smart tool holders, two types of smart cutting tools and a smart spindle for high speed drilling and precision turning purposes respectively. The smart cutting tools presented are force-based devices, which allow measuring the cutting force in real time. By monitoring the cutting force a suitable sensor feedback signal can be captured, which can then be applied for the smart machining. Furthermore, an overview of recent research projects on smart spindle development is provided, demonstrating that signal feedback is very closely correlated to the drilling through a multilayer composite board. Implementation aspects on the proposed smart cutting tool are also explored in the application of hybrid dissimilar material machining.

Development of Smart Tooling Concepts Applied to Ultraprecision Machining

2017 ◽  
Vol 5 (2) ◽  
Author(s):  
Chao Wang ◽  
Kai Cheng ◽  
Richard Rakowski
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Feedback Signal ◽  
Ultraprecision Machining ◽  
Precision Turning ◽  
High Speed Drilling ◽  
Smart Machining ◽  
Spindle Development

This paper presents smart tooling concepts applied to ultraprecision machining, particularly through the development of smart tool holders, two types of smart cutting tools, and a smart spindle for high-speed drilling and precision turning purposes, respectively. The smart cutting tools presented are force-based devices, which allow measuring the cutting force in real-time. By monitoring the cutting force, a suitable sensor feedback signal can be captured, which can then be applied for the smart machining. Furthermore, an overview of recent research projects on smart spindle development is provided, demonstrating that signal feedback is very closely correlated to the drilling through a multilayer composite board. Implementation aspects on the proposed smart cutting tool are also explored in the application of hybrid dissimilar material machining.

Investigation of the Effects of Microgrooved Cutting Tool in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Xingbang Chen ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Contact Length ◽  
High Speed Machining ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Cutting Inserts ◽  
1045 Steel

In this paper, numerical investigation of the effects of microgroove textured cutting tools in high speed machining of AISI 1045 is conducted using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of main cutting force, thrust force, and tool-chip contact length. It is found that microgrooved cutting tools generate lower cutting force and consequently lower the energy necessary for machining. This research provides insightful guidance for optimizing tool life and reducing energy consumption in high-speed machining of AISI 1045 steel.

The Application of FEA in High-Speed Cutting Tool

2011 ◽  
Vol 314-316 ◽  
pp. 1258-1261
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Material Model ◽  
Friction Model ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools parameters are determined by simulating the influences of cutting temperature, cutting force on the tools parameters using FEA.

A Strategy of Toolpath Generation for Finish Machining of Mold Cavity Based on Tool-Zmap Model

2009 ◽  
Vol 407-408 ◽  
pp. 273-278
Author(s):  
Yu Jun Cai ◽  
Chun Zheng Duan ◽  
Li Jie Sun
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Geometric Model ◽  
Cutting Tools ◽  
Mold Cavity ◽  
High Speed Machining ◽  
Cutting Tool Wear ◽  
Finish Machining ◽  
Toolpath Generation

A strategy of toolpath generation based on Tool-Zmap geometric model has been proposed to achieve efficient finish machining of mold cavity. Considering cutting tool wear, the finish machining of mold cavity was performed using variable cutting tools of different diameter. Each cutting tool only cuts the corresponding area to avoid identifying machining characteristic and poor rigidity of cutting tool during high speed machining. Finally, the validity of presented strategy was experimentally affirmed by a machining example.

Experimental Research on High-Speed Machining Pearlitic Gray Cast Iron

2006 ◽  
Vol 315-316 ◽  
pp. 459-463 ◽  
Author(s):  
Yi Wan ◽  
Zhan Qiang Liu ◽  
Xing Ai
Keyword(s):  
Cast Iron ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
Workpiece Surface ◽  
Tool Materials ◽  
Boron Nitrogen

High-speed machining (HSM) has received great interest because it leads to an increase of productivity and a better workpiece surface quality. However, tool wear increases dramatically due to the high temperature at the tool/workpiece interface. Proper selection of cutting tool and cutting parameters is the key process in high-speed machining. In this paper, experiments have been conducted to high speed milling pearlitic cast iron with different tool materials, including polycrystalline cubic boron nitrogen, ceramics and coated cemented carbides. Wear curves and tool life curves have been achieved at various cutting speeds with different cutting tools. If efficiency is considered, Polycrystalline Cubic Boron Nitrogen cutting tool materials are preferred in finish and semi-finish machining. According to the different hardness of cast iron, the appropriate range of cutting speed is from 850 m/min to 1200m/min.

Finite Element Modeling of Stresses Induced by High Speed Machining With Round Edge Cutting Tools

2005 ◽  
Author(s):  
Tugrul O¨zel ◽  
Erol Zeren
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Surface Properties ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Material Behavior ◽  
High Speed Machining ◽  
Element Modeling ◽  
Work Material

High speed machining (HSM) produces parts with substantially higher fatigue strength; increased subsurface micro-hardness and plastic deformation, mostly due to the ploughing of the cutting tool associated with residual stresses, and can have far more superior surface properties than surfaces generated by grinding and polishing. In this paper, a dynamics explicit Arbitrary Lagrangian Eulerian (ALE) based Finite Element Method (FEM) modeling is employed. FEM techniques such as adaptive meshing, explicit dynamics and fully coupled thermal-stress analysis are combined to realistically simulate high speed machining with an orthogonal cutting model. The Johnson-Cook model is used to describe the work material behavior. A detailed friction modeling at the tool-chip and tool-work interfaces is also carried. Work material flow around the round edge-cutting tool is successfully simulated without implementing a chip separation criterion and without the use of a remeshing scheme. Finite Element modeling of stresses and resultant surface properties induced by round edge cutting tools is performed as case studies for high speed machining of AISI 1045 and AISI 4340 steels, and Ti6Al4V titanium alloy.

scholarly journals Taguchi parametric study on the radial and tangential cutting forces in Dry High Speed Machining (DHSM)

10.30544/472 ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 303-316
Author(s):  
M. Hatami ◽  
H. Safari
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Parametric Study ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Machining ◽  
Cutting Speeds

In this paper, L8 Taguchi array is applied to find the most important parameters effects on the radial and tangential cutting forces of a Ti–6Al-4V ELI titanium alloy in dry high speed machining (DHSM). The experiments are performed in four cutting speeds of 150, 200, 250, and 300 m/min and two feed rates of 0.03 and 0.06 mm/rev. Also, two cutting tools in types of XOMX090308TR-ME06 of uncoated (H25) and TiAlN+TiN coated (F40M) are used. Results confirm that to minimize the resultant cutting force and radial cutting force, utilizing the lower feed rate and higher cutting speeds were considered as the best levels of factors to reach to its goal.

CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Han Wu ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
High Speed Machining ◽  
Rake Face ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045 steel. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A coupled Eulerian-Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 steel with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of orthogonal high speed cutting of AISI 1045 using microgrooved cutting tools. It is also concluded that microgrooved cutting tools can not effectively reduce the cutting force in high speed machining, which is contrary to the conclusion obtained for low speed machining in previous research. However, microgrooves on the rake face have influence on the austenite percentage in the chip near the rake face. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation in high speed machining of AISI 1045 steel.

Hard Nano-Crystalline Coatings for Cutting Tools

2007 ◽  
Vol 567-568 ◽  
pp. 185-188 ◽  
Author(s):  
Miroslav Piska
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Dry Cutting ◽  
Nano Crystalline ◽  
The Right ◽  
Machining Productivity ◽  
Hard Cutting ◽  
Cutting Tool Materials

Modern trends in metal cutting, high speed/feed machining, dry cutting and hard cutting set more demanding characteristics for cutting tool materials. The exposed parts of the cutting edges must be protected against the severe loading conditions and wear. The most significant coatings methods for cutting tools are PVD and CVD/MTCVD today. The choice of the right substrate or the right protective coating in the specific machining operation can have serious impact on machining productivity and economy. In many cases the deposition of the cutting tool with a hard coating increases considerably its cutting performance and tool life. The coating protects the tool against abrasion, adhesion, diffusion, formation of comb cracks and other wear phenomena.

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