Cutting high-performance materials with ultrasonically modulated cutting speed

2020 ◽  
Author(s):  
Armin Reif ◽  
Sebastian Sitzberger ◽  
Rolf Rascher
Keyword(s):  
High Performance ◽  
Cutting Speed

Study of a High Performance AFM Probe-Based Microscribing Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
Keith Bourne ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Tool Wear ◽  
High Performance ◽  
Cutting Speed ◽  
Rake Angle ◽  
Motion Platform ◽  
High Cutting Speed ◽  
Working Volume ◽  
Afm Probe ◽  
Tool Motion ◽  
Five Axis

In this paper, a mechanical microscribing process is described that combines AFM probe-based microscribing with a five-axis microscale machine tool motion platform in order to achieve high scribing speeds, a large working volume, and the capability of cutting curvilinear patterns of grooves. An experiment is described that demonstrates groove formation, groove shape, and tool wear when long grooves are formed using multiple tool passes. A second more systematic experiment is described in which short-distance single-pass cutting tests were used to explore the effects of cutting speed, nominal tool load, and AFM probe mounting angle on groove geometry, tool wear, effective rake angle, and chip formation. Lastly, an experiment is described in which a long curvilinear groove is cut. It is shown that the most well-formed grooves were cut and acceptable tool wear was achieved, when using a high cutting speed, high nominal tool load, and low probe mounting angle. The capability of cutting grooves as long at 82 mm but with depths of only a few hundred nanometers, using a single tool pass at cutting speeds as high at 25 mm/min is demonstrated.

Effect of weave structure on the slicing cut resistance of woven fabrics

2019 ◽  
Vol 90 (13-14) ◽  
pp. 1477-1494
Author(s):  
Magdi El Messiry ◽  
Shaimaa El-Tarfawy
Keyword(s):  
High Performance ◽  
Normal Load ◽  
Cutting Speed ◽  
Woven Fabrics ◽  
Woven Fabric ◽  
Weft Yarn ◽  
Fabric Structure ◽  
Yarn Count ◽  
Highly Correlated ◽  
Cutting Processes

Cutting processes using blades have found applications in many industries; for example, in garments, fiber–polymer composites, and high-performance fabric forming. In recent decades, the process of cutting the material using a robotic-controlled blade has raised concern about the value of the pressure and the cut force required for a certain type of woven fabric and the estimation of its value before the pressing and cutting process. A simple theoretical relation was established based on the fabric structure and yarn shear stress. The model formulation and experimental results to describe the basic theory of blade cutting fracture for woven fabric of different designs was derived. In this work, the experimental investigation of the effect of the fabric specifications, normal load, and the cutting speed on the cutting force was carried out, which indicates that the value of the specific cutting resistance of the fabric was found to be highly correlated with the fabric structure, warp and weft yarn count, Young’s modulus of the fabric, and fractional cover factors ratio ζ.

Optimization of Machining Parameters during Drilling of 7075 Aluminium Alloy

2012 ◽  
Vol 248 ◽  
pp. 20-25
Author(s):  
Abolfazl Golshan ◽  
Danial Ghodsiyeh ◽  
Soheil Gohari ◽  
Amran Bin Ayob ◽  
B.T. Hang Tuah Baharudin
Keyword(s):  
Aluminum Alloy ◽  
Performance Optimization ◽  
High Performance ◽  
Cutting Speed ◽  
Drilling Process ◽  
Machining Parameters ◽  
Algorithm Optimization ◽  
Drilling Parameters ◽  
Drill Diameter ◽  
Selection Of

Proper selection of drilling parameters is one of the significant challenges in drilling process. In this study, a new method for selection of optimal machining parameters during drilling operation is investigated. The present study deals with multiple-performance optimization of machining characteristics during drilling of 7075 aluminum alloy. The most commonly-used material in aerospace industry is aluminum alloy with zinc as the primary alloying element. The drilling parameters used for this experiment include cutting speed, feed rate and drill diameter while the two output parameters are surface roughness and dimension error. These outputs are specified to be optimized as a measure of process performance. The statistical model is generated from linear polynomial equations which are developed from different output responses when the machining parameters are changed. The Non-dominated Sorting Genetic Algorithm optimization results show high performance in solving the present problem.

scholarly journals Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

2016 ◽  
Vol 1136 ◽  
pp. 586-591 ◽  
Author(s):  
Jun Shinozuka ◽  
Habibah binti Jaharadak
Keyword(s):  
Aluminum Alloy ◽  
Heat Conduction ◽  
Temperature Distribution ◽  
High Performance ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Rake Face ◽  
Machining Performance ◽  
Unsteady Heat Conduction ◽  
Indexable Insert

Knowing temperatures at the tool-chip interface is extremely important to optimize the machining condition and to improve the machining performance, furthermore to design high performance materials. In order to grasp the temperature distribution at the tool-chip interface, this study has devised an indexable insert with seven pairs of built-in micro Cu/Ni thermocouples on the rake face near the cutting edge. This paper shows the performance of the indexable insert with built-in micro thermocouples developed. The thickness of each element of the micro thermocouple is approximately 15 μm. The result of unsteady heat conduction analysis employing FEM shows that the temperature difference by installing the micro thermocouples is less than 10 K or 1.2 %. The temperature measurement experiments by cutting of aluminum alloy were carried out by changing the cutting speed. The results provided the evidence that the temperature distribution at the tool-chip interface can be grasped with the indexable insert with built-in micro thermocouples developed.

scholarly journals On the Machinability Evolution in Asymmetric Milling of TC25 Ti Alloy Aiming at High Performance Machining

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7306
Author(s):  
Xueli Song ◽  
Hongshan Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
High Performance ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Balanced Development ◽  
Radial Depth ◽  
The Asymmetry

In this paper, the evolutions of cutting force, cutting temperature, and surface roughness, and the corresponding machinability in asymmetric up-milling of TC25 alloy are investigated. The results indicated that radial depth of cut generated opposite influence on the cutting force/cutting temperature versus surface roughness. The reason can be accounted as the intertwining of feed marks at low radial depth of cut, and the mechanism of hard cutting at a high radial depth of cut. Moreover, the asymmetry has a significant effect on the machinability in asymmetry up-milling TC25 alloy. Changing the asymmetry, i.e., the radial depth of cut, can alter the machinability while maintain the balanced development of various indexes. The machinability reaches the best when the radial depth of cut is ae = 8 mm. The axial depth of cut and feed per tooth should be selected as large as possible to avoid work hardening and to improve machining efficiency in asymmetric up-milling TC25 alloy. The cutting speed should be controlled within Vc = 100–120 m/min to obtain better machinability. On the basis of this research, it is expected to find optimized milling parameters to realize high efficiency milling of TC25 alloy.

FEATURES OF HIGH-SPEED THE SUPER-FINISHING DISCS CERAMIC

2020 ◽  
pp. 3-9
Author(s):  
V. G. Yuriev ◽  
Yu. M. Zubarev
Keyword(s):  
High Speed ◽  
High Performance ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Ceramic Materials ◽  
Processing Conditions ◽  
Duration Of Treatment ◽  
Metal Products ◽  
Stock Removal ◽  
The Impact

The possibility of providing high performance of super-finishing of ceramics based on the analysis of the processes of super-finishing of metal products is proved. For conducting experimental studies, a special installation has been developed, including a sharpening machine and a device for superfinishing. For such processing conditions, the necessity of using a low-rigidity technological system is justified. Discs made of ceramic materials of various machinability with diamond bars were super-finished at a cutting speed of up to 9.1 m/s and a clamping force of up to 90 N. Experimental data on the change in the value of cut allowance on the duration of treatment, the impact speed super-finishing of ceramic disks and grit sizes of diamond bars on the magnitude and rate of stock removal, roughness and waviness of machined surfaces and consumption of the tool. The results of super finishing of ceramic materials with processing of metal products are compared.

Experimental Investigation of Material Removal Mechanism in Grinding of Alumina by Single Grain Scratch Test

2013 ◽  
Vol 797 ◽  
pp. 96-102 ◽  
Author(s):  
Taghi Tawakoli ◽  
H. Kitzig ◽  
R. D. Lohner
Keyword(s):  
Material Removal ◽  
High Performance ◽  
Great Influence ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Scratch Test ◽  
Ultrasonic Vibrations ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Pile Up

Alumina is a material that is frequently used in high performance applications. Grinding of alumina is usually associated with micro-cracks which deteriorate surface quality. In order to get a deeper knowledge of the characteristics of material removal mechanisms in alumina during grinding with and without ultrasonic vibration of the workpiece, single grit scratch tests were performed in this research. The effect of the ultrasonic vibrations and cutting speed on the material removal mechanism of alumina was investigated in the chip thickness range of 0.53 μm which is common in precision grinding operations. It was shown that the material pile-up decrease with higher cutting speed. On the other hand, the transition from ductile to brittle mode of material removal occurs earlier in higher cutting speeds. The ultrasonic vibrations showed great influence in the cutting speed 30 m/s in reducing the pile-up values.

Study of a Novel Ceramic Tool Performance in the Machining of Ti-6Al-7Nb Alloys

MRS Advances ◽  
2019 ◽  
Vol 4 (55-56) ◽  
pp. 3007-3015
Author(s):  
Ricardo del Risco-Alfonso ◽  
Hector R. Siller ◽  
Roberto Pérez-Rodríguez ◽  
Arturo Molina
Keyword(s):  
Titanium Alloys ◽  
High Performance ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Point Of View ◽  
High Plasticity ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Ceramic Cutting Tool ◽  
Tool Performance

ABSTRACTConsidering their distinctive properties, titanium alloys are used in foremost industries, including the aeronautic, automotive and biomedical industries. The reduced machinability of titanium alloys is due to their low thermal conductivity and high plasticity behavior. In the biomedical sector, one of the most studied alloys is Ti-6Al-4V. In the case of the Ti-6Al-7Nb alloy, scarce investigations are identified, related to machinability studies. The machining of Ti-6Al-7Nb alloy requires the development of new tools with higher properties, which provide better performance. The objective of this study is to present the experimental results related to a novel ceramic cutting tool, in terms of cutting tool life and productivity, in the machining of Ti-6Al-7Nb alloy. A turning operation of a 25 mm diameter bar was performed; the cutting speed was varied in three levels. The results showed the high performance of this type of tools, from the point of view of machinability. The values of the obtained cutting forces are found in the ranges reported by the consulted literature using ceramic tools. The surface roughness values were considered appropriate, taking into account that the tool is recommended for roughing and semi-finishing operations. The most relevant results were obtained in terms of productivity, considering that the performance is 2.53 times higher than the presented in similar works.

Predictive Modeling and Optimization of High Performance Machining

2007 ◽  
Vol 10-12 ◽  
pp. 842-849
Author(s):  
Steven Y. Liang ◽  
Binti M. Abraham
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
High Performance ◽  
Manufacturing Systems ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Analytical Models ◽  
Machining Performance ◽  
Machining Processes ◽  
Workpiece Material

High performance machining refers to the material removal operation that delivers the maximum achievable part quality, process competitiveness, and ecological compatibility through strategic utilization of cutters, machine tools, operation configuration, and process parameters. It is rapidly emerging as a prerequisite to productivity and profitability of machining operations and associated manufacturing systems. To accomplish high performance machining, a thorough understanding of the underlying mechanics that affect the performance attributes such as tool life, part integrity, air quality, etc., and how it is attributed to tooling conditions, operation configuration, and process parameters, is required. This paper reviews and summarizes a series of analytical methodologies by coupling with studies performed at the Georgia Institute of Technology for the quantitative modeling of fundamental mechanics of machining in the context of thermal, mechanical, tribological, and metallurgical effects and their interactions. In this study, cutting stresses, residual stress and tool life are explicitly described as functions of tool geometries, cutting speed, chip load, cutting fluid properties, interface tribological conditions, and the cutter/workpiece material constants. These analytical models facilitate the prediction of machining performance thereby allowing the optimal planning of machining processes in pursuing maximum performance. An array of experimental cutting data is also presented in comparison to model-based predictions for the validation of all aspects of the machining mechanics analysis.

Parameteric Optimization of Surface Roughness in End Milling of Aluminium Rock Dust Composite

2015 ◽  
Vol 813-814 ◽  
pp. 382-387 ◽  
Author(s):  
K. Soorya Prakash ◽  
S. Sudhagar ◽  
M. Sakthivel ◽  
P.M. Gopal
Keyword(s):  
Surface Roughness ◽  
Particle Size ◽  
High Performance ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Weight Percentage ◽  
Recent Developments ◽  
Selection Of ◽  
Rock Dust

Recent developments in the composite materials with high performance increase its range of application most widely but the major disadvantage of these novel materials is machining. The selection of proper process parameters plays an important role in distinguishing machining quality. This work mainly concentrates on the selection of process parameter for minimizing the surface roughness in end milling operation for the newly developed aluminium rock dust metal matrix composite. Taguchi method is used to design and accordingly L27 orthogonal array with five factors viz particle size, weight percentage, cutting speed, feed and depth of cut each at three levels is employed. The experiments were performed in a CNC vertical machining center and corresponding surface roughness values are measured. From the collected data, ANOVA is performed and observations reveal that feed rate influence more on surface roughness followed by particle size, depth of cut, weight percentage and cutting speed.

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