Ultrasonic Cutting of Switchgrass and Miscanthus Stems

2018 ◽  
Vol 34 (2) ◽  
pp. 343-353
Author(s):  
A. Bulent Koc Koc ◽  
Bo Liu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Frequency ◽  
Cutting Speed ◽  
Particle Size Reduction ◽  
Element Analysis ◽  
Cutting Energy ◽  
High Frequency Vibrations ◽  
Ultrasound Assisted ◽  
Ultrasonic Cutting

Abstract. Ultrasound-assisted cutting has been used to cut materials with high precision, improved quality and reduced cutting forces. The research objective was to investigate the effects of high-frequency vibrations on the cutting force and cutting energy of switchgrass and miscanthus stems. Laboratory experiments were conducted on individual biomass stems at cutting speeds between 3 and 400 mm/s. An experimental cutting system with an ultrasound generator, an ultrasonic blade, a load cell, and a data acquisition system was developed. The custom designed blade was 5-cm wide and vibrated at 19.551 kHz with 2.8 µm tip vibration amplitude. There were significant measured differences in the cutting forces and cutting energies between conventional cutting and ultrasonic cutting of switchgrass and miscanthus stems (p < 0.05). These results suggest that the use of high-frequency vibrations reduce cutting force and cutting energy of both switchgrass and miscanthus stems. Ultrasound-assisted cutting reduced the cutting energy of switchgrass by 66.85% at 100 mm/s and miscanthus by 80.58% at 30 mm/s. However, ultrasonic cutting did not have a significant effect on the cutting force and cutting energy when the cutting speed was equal to or greater than the blade tip vibration speed. The results of this research should be useful for adapting the ultrasonic technology in biomass harvesting, particle size reduction, and processing equipment. Keywords: Biomass, Blades, Energy, Finite element analysis, Miscanthus, Switchgrass, Ultrasonics.

High Frequency Correction of Dynamometer for Cutting Force Observation in Milling

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
François Girardin ◽  
Didier Remond ◽  
Jean-François Rigal
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Frequency ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Wide Frequency Range ◽  
Force Measurements ◽  
Mean Oscillation ◽  
Number Of Factors ◽  
Frequency Correction

Piezoelectric dynamometers are widely used for cutting force measurements. Indeed, this device has the largest bandwidth for this kind of measurement. Nevertheless, the behavior of this device is not very well-known and its use is sometimes inappropriate for static and high frequency dynamic measurements. In this paper, a piezoelectric dynamometer is used for cutting force measurements in a milling case. Cutting forces in milling are discontinuous by nature due to successive inward and outward movements of tool-teeth on the workpiece. As a result, a bandwidth criterion based on cutting parameters is defined in order to permit clear observation of the mean oscillation of the cutting force. The frequency response of a dynamometer is then analyzed over a wide frequency range. A 2 kHz bandwidth can be defined for an efficient correction of cutting force. The dynamometer appears to be exploitable for higher frequencies up to at least 16 kHz though a large number of factors must be taken into account in the analysis. Finally, several lateral milling tests are performed by changing cutting speed, feed rate, and lubricant conditions. The correction of measurements permits highlighting certain particularities in the cutting force signals, such as the effect of shock of inward tool-teeth strokes on the workpiece, the specific behavior for outward tool-teeth strokes, and the effect of a lubricant on the variation in cutting forces.

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%.

scholarly journals Analytical, FEA, And Experimental Research of 2D-Vibration Assisted Cutting ( 2D-VAC) In Titanium Alloy Ti6Al4V

2021 ◽  
Author(s):  
Rendi Kurniawan ◽  
Farooq Ahmed ◽  
Gun Chul Park ◽  
Tae Jo Ko
Keyword(s):  
Residual Stress ◽  
Plastic Strain ◽  
Cutting Force ◽  
Frequency Modulation ◽  
High Frequency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Von Mises Stress ◽  
Micro Hardness ◽  
Micro Structure

Abstract In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, micro-structure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

scholarly journals The Influence of Tool Path Strategies on Cutting Force and Surface Texture during Ball End Milling of Low Curvature Convex Surfaces

2014 ◽  
Vol 2014 ◽  
pp. 1-14 ◽  
Author(s):  
Shaghayegh Shajari ◽  
Mohammad Hossein Sadeghi ◽  
Hamed Hassanpour
Keyword(s):  
Cutting Force ◽  
Surface Texture ◽  
Cutting Forces ◽  
Tool Path ◽  
End Milling ◽  
Cutting Speed ◽  
Quality Level ◽  
Convex Surfaces ◽  
Freeform Surface Machining ◽  
Selection Of

Advancement in machining technology of curved surfaces for various engineering applications is increasing. Various methodologies and computer tools have been developed by the manufacturers to improve efficiency of freeform surface machining. Selection of the right sets of cutter path strategies and appropriate cutting conditions is extremely important in ensuring high productivity rate, meeting the better quality level, and lower cutting forces. In this paper, cutting force as a new decision criterion for the best selection of tool paths on convex surfaces is presented. Therefore, this work aims at studying and analyzing different finishing strategies to assess their influence on surface texture, cutting forces, and machining time. Design and analysis of experiments are performed by means of Taguchi technique and analysis of variance. In addition, the significant parameters affecting the cutting force in each strategy are introduced. Machining strategies employed include raster, 3D-offset, radial, and spiral. The cutting parameters were feed rate, cutting speed, and step over. The experiments were carried out on low curvature convex surfaces of stainless steel 1.4903. The conclusion is that radial strategy provokes the best surface texture and the lowest cutting forces and spiral strategy signifies the worst surface texture and the highest cutting forces.

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.

Study on Fractal Characterization Laws of Cutting Force in CNC Turning Aeronautic Aluminium Alloy 7075-T651

2017 ◽  
Vol 748 ◽  
pp. 224-228 ◽  
Author(s):  
Bao Liang Xing ◽  
Jing Wang ◽  
Hui Ying Cao ◽  
Shu Zhong Zhang ◽  
Wei Wei ◽  
...  
Keyword(s):  
Fractal Dimension ◽  
Aluminium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Fractal Dimensions ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Main Effect

Based on the experiment of turning aluminium alloy (7075-T651), the relations between the fractal dimensions of cutting forces with machining parameters are studied. Cutting speed, feed speed and cutting depth are considered as the process parameters. The cutting force in turning aluminium alloy operation are measured and the fractal dimension are calculated using the algorithm of correlation dimension. From main effect plots the fractal dimensions of three directions of cutting forces are reduced with the increase of cutting speed, increased with the increase of cutting depth and insignificant with the increase of feed speed. The mathematic models of fractal dimension of cutting force are developed using response surface methodology (RSM). The results of the ANOVA show that cutting speed and cutting depth have remarkable influence to fractal dimension Dx, Dy and Dz.

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.

Fractal Characterization Analysis in CNC Milling Aluminium Alloy

2017 ◽  
Vol 748 ◽  
pp. 212-217 ◽  
Author(s):  
Zheng Mei Zhang ◽  
Bao Liang Xing ◽  
Jing Wang ◽  
Hui Ying Cao ◽  
Shao Hua Li
Keyword(s):  
Fractal Dimension ◽  
Aluminium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Fractal Dimensions ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Cutting Depth

Based on the experiment of milling aluminium alloy (7075-T651), the relations between the fractal dimensions of cutting forces with machining parameters are studied. Cutting speed, feed speed and cutting depth are considered as the process parameters. The cutting force in milling aluminium alloy operation are measured and the fractal dimension are calculated using the algorithm of correlation dimension. From main effect plots the fractal dimensions of three directions of cutting forces are reduced with the increase of cutting speed and increased with the increase of feed speed and cutting depth. The mathematic models of fractal dimension of cutting force are developed using response surface methodology (RSM). The results of the ANOVA show that feed speed and cutting depth have remarkable influence to fractal dimension Dx and Dy, cutting speed and feed speed for Dz.

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