scholarly journals Modeling and Optimizing the Effects of Insert Angles on Hard Turning Performance

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Pham Minh Duc ◽  
Mai Duc Dai ◽  
Le Hieu Giang
Keyword(s):  
Mathematical Model ◽  
Hard Turning ◽  
Tangential Force ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Cutting Edge ◽  
Turning Process ◽  
Nose Radius ◽  
Positive Effects ◽  
Feed Force

To analyze hard turning performance characteristics, a new mathematical model was developed for the hard turning process, and cutting force (CF), another important response for cutting machining, was also studied in the present work. The analysis of the mathematical model and experimental results revealed that thrust force (Fy) was the largest, followed by tangential force (Fz) and feed force (Fx). The resultant CF was most influenced by inclination angle (IA) with 25.02%, followed by rake angle (RA) (14.26%) and cutting edge angle (CEA) (10.04%). Increasing CEA changed the position of cutting on the tool-nose radius and increased local negative RA and correspondingly local clearance angle (CA). Meanwhile, increasing negative RA and IA resulted in larger local negative RA and CA. Moreover, local RA and local CA were the main geometric factors affecting surface roughness (SR), tool wear (TW), and CF. Increasing local negative RA resulted in higher SR and CF. In contrast, increasing local CA resulted in lower SR, TW, and CF. Under specific conditions, the positive effects of the local CA overcame the negative effects of the local negative RA, leading to a simultaneous decrease in SR and TW. The proposed novel mathematical model can be further applied to calculate local CF, cutting temperature, and TW for each cutting-edge element, to analyze and optimize the hard turning process.

Predicting the Effects of Cutting Parameters and Tool Geometry on Hard Turning Process Using Finite Element Method

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Xueping Zhang ◽  
Shenfeng Wu ◽  
Heping Wang ◽  
C. Richard Liu
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Hard Turning ◽  
Tangential Force ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Rake Angle ◽  
Fe Model ◽  
Turning Process ◽  
Nose Radius

To explore the effects of cutting speed, feed rate and rake angle on chip morphology transition, a thermomechanical coupled orthogonal (2-D) finite element (FE) model is developed, and to determine the effects of tool nose radius and lead angle on hard turning process, an oblique (3-D) FE model is further proposed. Three one-factor simulations are conducted to determine the evolution of chip morphology with feed rate, rake angle, and cutting speed, respectively. The chip morphology evolution from continuous to saw-tooth chip is described by means of the variations of chip dimensional values, saw-tooth chip segmental degree and frequency. The results suggest that chip morphology transits from continuous to saw-tooth chip with increasing feed rate and cutting speed, and changing a tool’s positive rake angle to negative rake angle. There exists a critical cutting speed at which the chip morphology transfers from continuous to saw-tooth chip. The saw-tooth chip segmental frequency decreases as the feed rate and the tool negative rake angle value increases; however, it increases almost linearly with the cutting speed. The larger negative rake angle, the larger feed rate and higher cutting speed dominate saw-tooth chip morphology while positive rake angle, small feed rate and low cutting speed combine to determine continuous chip morphology. The 3-D FE model considers tool nose radii of 0.4 mm and 0.8 mm, respectively, with tool lead angels of 0 deg and 7 deg. The model successfully simulates 3-D saw-tooth chip morphology generated by periodic adiabatic shear and demonstrates the continuous and saw-tooth chip morphology, chip characteristic line and the material flow direction between chip-tool interfaces. The predicted chip morphology, cutting temperature, plastic strain distribution, and cutting forces agree well with the experimental data. The oblique cutting process simulation reveals that a bigger lead angle results in a severer chip deformation, the maximum temperature on the chip-tool interface reaches 1289 deg, close to the measured average temperature of 1100 deg; the predicted average tangential force is 150N, with 7% difference from the experimental data. When the cutting tool nose radius increases to 0.8 mm, the chip’s temperature and strain becomes relatively higher, and average tangential force increases 10N. This paper also discusses reasons for discrepancies between the experimental measured cutting force and that predicted by finite element simulation.

Predicting the Effects of Tool Nose Radius and Lead Angle on Hard Turning Process Using 3D Finite Element Method

2010 ◽  
Author(s):  
Xueping Zhang ◽  
Heping Wang ◽  
C. Richard Liu
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element ◽  
Hard Turning ◽  
Tangential Force ◽  
Chip Morphology ◽  
Turning Process ◽  
Nose Radius ◽  
Lead Angle ◽  
Tool Nose Radius

Finite element method (FEM) has been qualified as an excellent method to analyze machining processes. Many researchers commonly adopt an orthogonal FE model to simulate hard turning process without considering the effect of tool nose radius and/or lead angle. However, the PCBN cutting tools usually possess a nose radius of 0.4mm to 0.8mm, which equals to the magnitude of cutting depth/feed in hard turning. To explore the effect of tool nose radius and rake angle on hard turning AISI 52100 steel process, an explicit dynamic thermo-mechanical three-dimensional (3D) FEM is developed. The model considers tool nose radius as 0.4mm and 0.8mm, respectively with a tool lead angle of 0° and 7°. The model successfully simulates 3D saw-tooth chip morphology generated by periodic adiabatic shear and demonstrates the continuous and saw-tooth chip morphology, chip characteristic line and the material flow direction between the chip-tool interfaces. The predicted chip morphology, cutting temperature, plastic strain distribution and cutting forces agrees well with the experimental data. The oblique cutting process simulation reveals that larger lead angle enables work material deformation more severely, the maximum temperature on the chip-tool interface reaches 1289°, close to the measured average temperature of 1100°; the predicted average tangential force is 150N, with 7% difference from the experimental data. When the cutting tool nose radius increases to 0.8mm, the chip’s temperature and strain becomes relatively higher, and average tangential force increases 10N. This paper also discusses the disagreement between the predicted and experimental cutting force.

A Study on Cutting Temperatures of Turning Stainless Steel with Chamfered Main Cutting Edge Nose Radius Tools

2009 ◽  
Author(s):  
Chung-Shin Chang
Keyword(s):  
Stainless Steel ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Heat Transfer Analysis ◽  
Nose Radius ◽  
Element Analysis ◽  
Inverse Heat Transfer ◽  
Frictional Forces ◽  
P Type

Temperatures of the carbide tip’s surface when turning stainless steel with a chamfered main cutting edge nose radius tool are investigated. The mounting of the carbide tip in the tool holder is ground to a nose radius as measured by a toolmaker microscope, and a new cutting temperature model developed from the variations in shear and friction plane areas occurring in tool nose situations are presented in this paper. The frictional forces and heat generated in the basic cutting tools are calculated using the measured cutting forces and the theoretical cutting analysis. The heat partition factor between the tip and chip is solved by the inverse heat transfer analysis, which utilizes the temperature on the P-type carbide tip’s surface measured by infrared as the input. The tip’s carbide surface temperature is determined by finite element analysis (FEA) and compared with temperatures obtained from experimental measurements. Good agreement demonstrates the accuracy of the proposed model.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

scholarly journals The Outcome of Turning Factors on the Machining Characteristics While Turning 655M13 Steel Alloy using Tialn Coated Carbide Insert

2020 ◽  
Vol 9 (3) ◽  
pp. 1251-1260 ◽  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Models ◽  
Tangential Force ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Steel Alloy ◽  
Nose Radius ◽  
Feed Force ◽  
Coated Carbide

This exploration is carried out to reveal the outcome of turning factors such as cutting velocity, depth of cut and feed rate on the surface roughness, mean cutting force and tool-work interface temperature on turning cylindrical 655M13 steel alloy components. The experiments are designed based on (33) full factorial design and conducted on a turning centre with Titanium Aluminium Nitride (TiAlN) layered carbide tool of 0.8mm nose radius, simultaneously cutting forces such as feed force, thrust force and tangential force and the tool-work interface temperature are observed using calibrated devices. The surface roughness of the turned steel alloy parts is deliberated by means of a precise surface roughness apparatus. Prediction models are created for average surface roughness, mean cutting force and tool-work interface temperature by nonlinear regression examination with the aid of MINITAB numerical software. The optimum machining conditions are confirmed with the aid of a Genetic Algorithm. The outcome of each turning factor on the surface roughness, mean cutting force and tool-work interface temperature is studied and presented accordingly.

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

Material Plastic Side Flow and White Layer in Hardened Steel GCr15 Precision Turning

2015 ◽  
Vol 667 ◽  
pp. 194-199
Author(s):  
Guang Jun Chen ◽  
Xiao Qin Zhou ◽  
Bai Ting He ◽  
Meng Ya ◽  
Zhe Hao Ba ◽  
...  
Keyword(s):  
Hard Turning ◽  
White Layer ◽  
Rake Angle ◽  
Bearing Steel ◽  
Hardened Steel ◽  
Tempered Martensite ◽  
Nose Radius ◽  
Side Stream ◽  
Fine Surface ◽  
Side Flow

Turning instead of grinding of the hardened steel is an environmentally cleaner production technology and green fabrication technique. Using the negative rake angle basic shape blades of Mountain of Sweden Sandvik Coromant PCBN7015 cut hardened bearing steel GCr15 and observe fine surface under microscopic condition.. Microscopic observation showed that there was side stream between hard turning two knife marks forming carinata. Side stream level aggravate on the fine surface with the enlargement of Tool Nose radius. The White layer of hard turning fine surface is divided into three areas. White-bright zone is made up of Cryptocrystalline martensite, Dark gray zone is made up of tempered martensite, Grayish zone is made up of the original martensite. This research will enrich theory of hard turning.

Investigation of Relation between Straightness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 789-790 ◽  
pp. 812-820 ◽  
Author(s):  
Thararath Shansungnoen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Conditions ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Force Ratio ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The objective of this research is to examine the relation between the straightness and the cutting force ratio during the CNC turning process. The cutting force is monitored and obtained by installing the dynamometer on the turret of CNC turning machine. The relation between the cutting force ratio and the straightness is investigated under the various cutting conditions, which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the straightness can be improved with an increase in cutting speed, tool nose radius and rake angle. The relation between the dynamic cutting force and straightness profile can be proved by checking the frequency of the cutting force in frequency domain with the use of the Fast Fourier Transform (FFT), which is the same as the straightness profile. Hence, the cutting force ratio can be used to predict the straightness during the cutting regardless of the cutting conditions. The cutting force ratio is proposed to predict the straightness during turning process by employing the exponential function for the sake of straightness. The multiple regression analysis has been utilized to calculate the regression coefficients of the in-process prediction of straightness model by using the least square method at 95% confident level. It has been proved by the cutting tests that the in-process straightness can be predicted during the cutting within ±10% measured straightness with the high accuracy of 91.85%.

Achieving Optimal Process Parameters during Hard Turning of AISI 52100 Bearing Steel Using Hybrid GRA-PCA

2019 ◽  
Vol 818 ◽  
pp. 87-91 ◽  
Author(s):  
P. Umamaheswarrao ◽  
D. Ranga Raju ◽  
K.N.S. Suman ◽  
B. Ravi Sankar
Keyword(s):  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Input Parameters

In the present work hard turning of AISI 52100 steel has been performed using Polycrystalline cubic boron nitride (PCBN) tools. The input parameters considered are cutting speed, feed, depth of cut, nose radius and negative rake angle and the measured responses are machining force and workpiece surface temperature. Experiments are planned as per Central Composite Design (CCD) of Response Surface Methodology (RSM). The effect of input parameters and their interactions are discussed with main effects plot. Further, the multi-objective optimization scheme is proposed by adopting Grey Relational Analysis (GRA) coupled with Principle Component Analysis (PCA). Results demonstrated that speed is the most significant factor affecting the responses followed by negative rake angle, feed, depth of cut, and nose radius. The optimum cutting parameters obtained are cutting speed 1000 rpm, feed 0.02 mm/rev, depth of cut 0.5 mm, Nose radius 1 mm and Negative rake angle 5o.

scholarly journals Numerical simulation of two tool turning process

2018 ◽  
Vol 192 ◽  
pp. 01001 ◽  
Author(s):  
Kalidasan Rathinam ◽  
Sandeep Kumar
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Element Model ◽  
Separation Distance ◽  
Recrystallization Temperature ◽  
Turning Process ◽  
Element Analysis ◽  
Feed Force

Double tool turning process is used to improve productivity. A 2D finite element model was developed using commercially available finite element analysis software Abaqus 6.13. The workpiece and the cutting tool materials are modelled as elasto-plastic and elastic material respectively. Johnson-Cook damage criterion was used for chip separation. The friction between the cutting tool and the workpiece is modelled based on penalty contact approach. The coefficient of friction between the chip and the first and second cutting tool was taken as 0.8 and 0.6 respectively. In this numerical investigation the effect tool separation distance over the cutting force, feed force and cutting temperature were studied. Three different tool separation distances were considered. The simulation result shows that cutting force and feed force of the front cutting tool and the rear cutting tool do not change appreciably with the variation of the tool separation distance. It was revealed that the temperature rise of the work material due to machining by two cutting tool is well below the recrystallization temperature. Hence the forces on front and rear cutting tool remain same for various tool separation distances. It was also observed that the cutting temperatures remained unchanged for the various tool separation distances.

Sign in / Sign up

Export Citation Format

Share Document