scholarly journals Multiobjective Optimization of Tool Geometric Parameters Using Genetic Algorithm

Complexity ◽  
2018 ◽  
Vol 2018 ◽  
pp. 1-14 ◽  
Author(s):  
Maohua Du ◽  
Zheng Cheng ◽  
Yanfei Zhang ◽  
Shensong Wang
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Design Theory ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Functional Relation ◽  
Rake Angle ◽  
Geometric Parameters

Tool geometric parameters have a huge impact on tool wear. Up to now, there are only a few researches on tool geometric parameters and optimization, and the single objective function of parameter optimization used by researchers during high-speed machining (HSM) mainly is the minimum cutting force. However, the elevated cutting temperature also greatly affects tool wear due to the numerous cutting heat generation. Thus, to reduce tool wear, it is the most fundamental approach to taking into account the comprehensive control of the cutting force and cutting temperature because they are the two most important physical quantities in metal cutting processes. This work proposes a new optimization idea of the cutting-tool’s multi geometric parameters (three main parameters: rake angle, clearance angle, and cutting edge radius) with two objective functions (the cutting force and the temperature). Based on the response surface method (RSM), we have established the modified functional relation models of the influence of tool geometric parameters on the cutting force and temperature according to the finite element simulation results in high-speed cutting of Ti6Al4V. Then the models are solved by using a genetic algorithm, and the optimal tool geometric parameters values that can concurrently control the two objectives in their minimum values are obtained. The advantages lie in the strategy of the separate models of the cutting force and cutting temperature owing to their different dimensions and the solution of the models through giving the cutting force and cutting temperature different weight coefficients. The optimal results are verified by experiments, which shows that the optimal tool geometric parameters are very effective and vital for ensuring both the cutting force and the cutting temperature not too high. This work is of great significance to the cutting tool design theory and its manufacturing for reducing tool wear.

Research on the Wear Process of High Speed Cutting Ni-Based Superalloy

2014 ◽  
Vol 800-801 ◽  
pp. 102-106
Author(s):  
Jun Zhou ◽  
Ming Pu Liu ◽  
Hong Qi Sun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Wear Mechanism ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Wear Process ◽  
High Speed Cutting ◽  
Cutting Tool Wear

As the main method of high efficiency cutting Ni-based superalloy, high-speed cutting can not but intensify the cutting-tool wear for the high cutting force and cutting temperature. So, it is very necessary to study the process of cutting-tool wear and wear mechanism, especially, the effect of cutting-tool wear on the cutting force, cutting temperature and surface roughness of machined workpiece. In this paper, investigation of tool wear in high-speed cutting is proposed, the PCDTiAlN carbide insert is used in the experiment, the cutting-tool wear and the corresponding cutting force, cutting temperature and surface roughness of machined workpiece is detected. It indicates that the cutting force, cutting temperature and surface roughness of machined workpiece is changed corresponding the cutting-tool wear,the wear process of coated tool include the coated material wears and base material wears,the wear mechanism is complex. Key word: superalloy, high-speed cutting, tool wear, wear form ; .

scholarly journals Finite Element Modeling of the Effect of Tool Rake Angle on Cutting Force and Tool Temperature during High Speed Machining of AISI 1045 Steel

2014 ◽  
Vol 939 ◽  
pp. 194-200
Author(s):  
Shamsuddin Sulaiman ◽  
Mohd K.A. Ariffin ◽  
A. Roshan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
High Speed Machining ◽  
Tool Temperature ◽  
Aisi 1045 ◽  
Cutting Speeds

A finite element model (FEM) of an orthogonal metal-cutting process is used to study the influence of tool rake angle on the cutting force and tool temperature. The model involves Johnson-Cook material model and Coulomb’s friction law. A tool rake angle ranging from 0° to 20° and a cutting speed ranging from 300 to 600 m/min were considered in this simulation. The results of this simulation work are consistent optimum tool rake angle for high speed machining (HSM) of AISI 1045 medium carbon steel. It was observed that there was a suitable rake angle between 10° and 18° for cutting speeds of 300 and 433 m/min where cutting force and temperature were lowest. However, there was not optimum rake angle for cutting speeds of 550 and 600 m/min. This paper can contribute in optimization of cutting tool for metal cutting process.

Finite Element Analysis of the Effects of Tool-Chip Friction on Cutting Temperature Field

2010 ◽  
Vol 44-47 ◽  
pp. 425-429
Author(s):  
Sheng Yu Liu ◽  
Jian Ying Guo
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Friction Coefficient ◽  
Tool Wear ◽  
Inclination Angle ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Element Analysis ◽  
Cutting Processes

The heat generation caused by tool-chip friction and chip deformation strongly influences the tool wear and tool life in metal cutting processes. The focus of this paper is on the effect of tool-chip on cutting temperature field. A series of ¬finite element simulations have been performed, in which a modifi¬ed Coulomb friction law is used to model the friction along tool–chip interface. A tool rake angle ranging from 10° to 45°, a inclination angle ranging from 0° to 20°, and a friction coefficient ranging from 0.1 to 0.6 have been considered in simulations. The results of these simulations show that the maximum cutting temperature increases with the increasing of tool-chip friction coefficient at different rake angle and inclination angle. The form of tool wear mainly appears as crater wear when the friction coefficient is less than 0.5, and the cutting edge tends to split when the friction coefficient is larger than 0.6.

Lubrication Effect of Smeared Oil on Workpiece Surface in Intermittent Cutting With Very Short Cutting Duration

2020 ◽  
Author(s):  
Yoshiki Nakamura ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Satoru Maegawa ◽  
Xiaoxu Liu
Keyword(s):  
Cutting Force ◽  
Temperature Rise ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Frictional Heat ◽  
Low Viscosity ◽  
Ti Alloys ◽  
Intermittent Cutting

Abstract In the metal cutting, generally, application of lubricant to a cutting edge is one of the methods in order to suppress temperature rise of the cutting edge by reducing frictional heat. However, the reduction in friction with lubricant disappears at higher temperature environment because of the loss of lubricant oiliness associated with temperature rise. Conversely, this reduction effect might work only in the initial stage immediately after cutting edge /work engagement because the temperature is not so high. Therefore, if the cutting duration of each blade of end-mill is shorten by limiting the cutting length per once, the cutting temperature can be suppressed to be lower than the moderate magnitude for lubrication. On the other hand, Ti-alloys with low thermal conductivity would experience quite high temperature increase during the high-speed cutting process. Therefore, it is thought that lubricant cannot be used properly with conventional cutting methods. In this study, the high-speed milling method mentioned above was used to implement the machining of Ti-alloys, and the lubricant effects of different types oils were compared from two aspects as tool wear and cutting force. As a result, when using low-viscosity synthetic ester oil, the damage to the cutting edge was suppressed most. At the same time, there was no fluctuation in cutting force by repeated machining. From this result, it was suggested that the lubricant performance, in intermittent cutting with very short cutting duration, depends on the heat resistance and permeability of the oil.

Optimization of Twist Drill’s Geometry for Cast Iron

2010 ◽  
Vol 431-432 ◽  
pp. 555-558 ◽  
Author(s):  
Xiao Hu Zheng ◽  
Hong Zhou Zhang ◽  
Kai Xue ◽  
Ming Chen ◽  
Yun Shan Zhang
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Double Point ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Drilling Performance

A new special drill is developed for iron cast drilling. The special drill has double point angle and 0°chisel rake angle which can decrease cutting force, tool wear and cutting temperature. Drilling performance is evaluated by trust force, torque, tool wear. The results indicate that new special drill is suitable for iron cast drilling with small cutting force and long tool life.

The Investigation of Tool Wear in High Speed Cutting INCONEL718

2010 ◽  
Vol 33 ◽  
pp. 347-350
Author(s):  
J. Zhou ◽  
R.D. Han
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
High Efficiency ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Main Method ◽  
High Speed Cutting ◽  
Cutting Tool Wear

As the main method of high efficiency machining Ni-based superalloy, high-speed cutting can not but intensify the cutting-tool wear. So, it is very necessary to find the rule of cutting-tool wear in high-speed cutting superalloy, especially, the effect of cutting-tool wear on the cutting force, cutting temperature and surface roughness of machined workpiece. In this paper, the PCDTiAlN cemented carbide insert is used in the experiment, the value of cutting-tool wear and the corresponding cutting force, cutting temperature and surface roughness of machined workpiece is measured. It indicates that the cutting force, cutting temperature and surface roughness of machined workpiece is changed corresponding the cutting-tool wear changes, and cutting-tool is serious, for example, the crater wear expands quickly; the boundary wear is obvious.

Predictive Modeling of Flank Wear in Turning Under Flood Cooling

2006 ◽  
Vol 129 (3) ◽  
pp. 513-519 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Metal Cutting ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machining Process ◽  
Analytical Models ◽  
Dynamic Strain ◽  
Process Conditions ◽  
Force Analysis

The objective of this paper is to present physical and quantitative models for the rate of tool flank wear in turning under flood cooling conditions. The resulting models can serve as a basis to predict tool life and to plan for optimal machining process parameters. Analytical models including cutting force analysis, cutting temperature prediction, and tool wear mechanics are presented in order to achieve a thermo-mechanical understanding of the tool wear process. The cutting force analysis leverages upon Oxley’s model with modifications for lubricating and cooling effect of overhead fluid application. The cutting temperature was obtained by considering workpiece shear deformation, friction, and heat loss along with a moving or stationary heat source in the tool. The tool wear mechanics incorporate the considerations of abrasive, adhesion, and diffusion mechanisms as governed by contact stresses and temperatures. A model of built-up edge formation due to dynamic strain aging has been included to quantify its effects on the wear mechanisms. A set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the material-dependent coefficients in the models. Experimental cutting data were also used to validate the predictive models by comparing cutting forces, cutting temperatures, and tool lives under various process conditions. The results showed that the predicted tool lives were close to the experimental data when the built-up edge formation model appropriately captured this phenomenon in metal cutting.

Numerical Simulation of Cutting Force and Temperature Field in High Speed Machining of Titanium Alloys

2010 ◽  
Vol 37-38 ◽  
pp. 731-734 ◽  
Author(s):  
Cong Ming Yan ◽  
You Xi Lin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Rake Angle ◽  
Maximum Temperature ◽  
High Speed Machining ◽  
Force Fluctuation ◽  
Cutting Force Fluctuation

Improvements in manufacturing technologies require better modeling and simulation of metal cutting processes. A fully thermal-mechanical coupled finite element analysis (FEA) was applied to model and simulate the high speed machining of TiAl6V4. The development of serrated chip formation during high speed machining was simulated. The effects of rake angle on chip morphology, cutting force and the evolution of the maximum temperature at the tool rake were analyzed with the finite element model. The simulation results show that the segmented chip formation results in cutting force fluctuation. Although the segmentation frequency of the chip increases with the increase of the rake angle, the degree of segmentation becomes weaker and the cutting force fluctuation amplitude decreases. The predicted temperature distribution during the cutting process is consistent with the experimental results given in a literature.

scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

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