Method for determining rational cutting modes and cutting tool geometry when turning titanium alloys based on a mathematical model of error generation

2020 ◽  
pp. 49-57
Author(s):  
Tatyana A. Larionova ◽  
Sergey A. Lubomudrov ◽  
Evgeny O. Larionov
Keyword(s):  
Mathematical Model ◽  
Titanium Alloys ◽  
Cutting Tool ◽  
Tool Geometry ◽  
Error Generation ◽  
Cutting Modes

Machinability of Heat-Resistant Titanium Alloys during Turning

2021 ◽  
Vol 1022 ◽  
pp. 62-70
Author(s):  
Tatyana Larionova ◽  
Sergei A. Lyubomudrov ◽  
Evgeniy Larionov
Keyword(s):  
Mathematical Model ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Experimental Research ◽  
Cutting Tool ◽  
Technological System ◽  
Elastic Deformations ◽  
Heat Resistant ◽  
Processing Modes ◽  
Mechanical And Service Properties

The article discusses the properties and features of heat-resistant titanium alloys. The microstructure of a new titanium alloy VT41, its mechanical and service properties after various processing modes are presented. The main problems in the machining of difficult-to-machine titanium alloys are considered. The developed mathematical model of the formation of errors in turning titanium alloys, taking into account thermal deformations and dimensional wear of the cutting tool, elastic deformations of the technological system, is described. The paper presents the results of experimental research on turning of heat-resistant titanium alloy VT41 on a multi-parameter stand.

Machinability Evaluation of Inclined Planetary Motion Milling System for Difficult-to-Cut Materials

2015 ◽  
Vol 656-657 ◽  
pp. 320-327 ◽  
Author(s):  
Hidetake Tanaka ◽  
Toma Yoshita
Keyword(s):  
Cutting Tool ◽  
Rotation Axis ◽  
Tool Geometry ◽  
Planetary Motion ◽  
Orbital Drilling ◽  
Drilling Technique ◽  
Cutting Model ◽  
Cutting Experiments ◽  
Tool Rotation ◽  
The Revolution

CFRP and Titanium alloy, which are known as difficult-to-cut materials have been widely used as structural material in aviation industries. The orbital drilling is one of an effective drilling technique for the industries. However this technique has some disadvantages such as increase of cutting force due to cutting with tool center point, inertial vibration generated by revolution and high installation cost. In order to improve the disadvantages, we have invented a new drilling technique which is called inclined planetary motion milling. The inclined planetary motion milling and the planetary mechanism drilling has two axes of cutting tool rotation axis and revolution axis. Cutting tool rotation axis of the orbital drilling is moved parallel to the revolution axis in eccentric. On the other hand, in the case of the inclined planetary motion milling, eccentric of the cutting tool rotation axis is realized by inclination of a few degrees from the revolution axis. Therefore, the movement of eccentric mechanism can be reduced by comparison with the orbital drilling because inclined angle is smaller than eccentricity of the cutting tool tip. As a result, eccentric mechanism can be downsized and inertial vibration is reduced. In the study, a geometrical cutting model of inclined planetary motion milling was set up. The theoretical surface roughness of the inside of drilled holes by use of two types cutting tool geometry were calculated based on the model. And cutting experiments using the new prototype for CFRP were carried out in order to evaluate the effect on machinability with change of cutting point atmosphere. In addition, optimal cutting condition was derived according to cutting experiments for titanium alloys utilizing the orthogonal array.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Mathematical Model for the Influence of Machine Tool Parts Deformation on Machining Accuracy

2014 ◽  
Vol 556-562 ◽  
pp. 1354-1357
Author(s):  
Li Gong Cui ◽  
Gui Qiang Liang ◽  
Fang Shao
Keyword(s):  
Mathematical Model ◽  
Mathematical Method ◽  
Machine Tool ◽  
Cutting Tool ◽  
Lower Surface ◽  
Design Stage ◽  
Machining Accuracy ◽  
Cutting Point ◽  
The Mathematical Model

This paper presents a mathematical method to analyze the influence of each machine tool part deformation on the machining accuracy. Taking a 3-axis machine tool as an example, this paper divides the machine tool into the cutting tool sub-system and workpiece sub-system. Taking the deformation of lower surface of the machine bed as the research target, the mathematical model of the deformation on the displacement of the cutting point was established. In order to distribute the stiffness of each part, the contribution degree of each part on the machining accuracy was analyzed. Using this mathematical model, the stiffness of each part can be distributed at the design stage of the machine tool, and the machining accuracy of the machine tool can be improved economically.

Model for Optimization of the Tool Life and the Cutting Speed for Maximum Productivity at Drilling of the Steel 2NiCr185

2015 ◽  
Vol 760 ◽  
pp. 433-438 ◽  
Author(s):  
Ovidiu Blăjină ◽  
Aurelian Vlase ◽  
Marius Iacob
Keyword(s):  
Mathematical Model ◽  
Stainless Steel ◽  
Tool Life ◽  
Stainless Steels ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Research Directions ◽  
Maximum Productivity ◽  
Optimum Cutting ◽  
New Research

The research in the last decade regarding their cutting machinability have highlighted the insufficiency of the data for establishing of the optimum cutting processing conditions and the optimum cutting regime. The purpose of this paper is the optimization of the tool life and the cutting speed at the drilling of the stainless steels in terms of the maximum productivity. A nonlinear programming mathematical model to maximize the productivity at the drilling of a stainless steel is developed in this paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the proposed mathematical model. The use of this productivity model allows greater accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The obtained results can be used in production activity, in order to increase the productivity of the stainless steels machining. Finally the paper suggests new research directions for the specialists interested in this field.

The Ledge Tool: A New Cutting Tool Insert

1985 ◽  
Vol 107 (2) ◽  
pp. 99-106 ◽  
Author(s):  
R. Komanduri ◽  
M. Lee
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tool ◽  
Metal Removal ◽  
Face Milling ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Peripheral Milling ◽  
Cemented Carbide Tool ◽  
Edge Wear

The salient features of a simple, wear-tolerant cemented carbide tool are described. Results are presented for high-speed machining (3 to 5 times the conventional speeds) of titanium alloys in turning and face milling. This tool, termed the ledge cutting tool, has a thin (0.015 to 0.050 in.) ledge which overhangs a small distance (0.015 to 0.060 in.) equal to the depth of cut desired. Such a design permits only a limited amount of flank wear (determined by the thickness of the ledge) but continues to perform for a long period of time as a result of wear-back of the ledge. Under optimum conditions, the wear-back occurs predominantly by microchipping. Because of geometric restrictions, the ledge tool is applicable only to straight cuts in turning, facing, and boring, and to face milling and some peripheral milling. Also, the maximum depth of cut is somewhat limited by the ledge configuration. In turning, cutting time on titanium alloys can be as long as ≈ 30 min. or more, and metal removal of ≈ 60 in.3 can be achieved on a single edge. Wear-back rates in face milling are about 2 to 3 times higher than in straight turning. The higher rates are attributed here to the interrupted nature of cutting in milling. Use of a grade of cemented carbide (e.g., C1 Grade) which is too tough or has too thick a ledge for a given application leads to excessive forces which can cause gross chipping of the ledge (rapid wear) and/or excessive deflection of the cutting tool with reduced depth of cut. Selection of a proper grade of carbide (e.g., Grades C2, C3, C4) for a given application results in uniform, low wear-back caused by microchipping. Because of the end cutting edge angle (though small, ≈ 1 deg) used, the ledge tool can generate a slight taper on very long parts; hence an N.C. tool offset may be necessary to compensate for wear-back. The ledge tool is found to give excellent finish (1 to 3 μm) in both turning and face milling. In general, conventional tooling with slight modifications can be used for ledge machining. The ledge tool can also be used for machining cast iron at very high speeds.

Computation of Optimal Workpiece Orientation for Multi-axis NC Machining of Sculptured Part Surfaces

2002 ◽  
Vol 124 (2) ◽  
pp. 201-212 ◽  
Author(s):  
Stephen P. Radzevich ◽  
Erik D. Goodman
Keyword(s):  
Cutting Tool ◽  
Nc Machining ◽  
Numerical Control ◽  
Tool Geometry ◽  
Geometric Problem ◽  
Part Surface ◽  
Nc Machine ◽  
New Type ◽  
Five Axis ◽  
Workpiece Orientation

Optimal workpiece orientation for multi-axis sculptured part surface machining is generally defined as orientation of the workpiece so as to minimize the number of setups in 4-, 5- or more axis Numerical Control (NC) machining, or to allow the maximal number of surfaces to be machined in a single setup on a three-, four-, or five-axis NC machine. This paper presents a method for computing such an optimal workpiece orientation based on the geometry of the part surface to be machined, of the machining surface of the tool, and of the degrees of freedom available on the multi-axis NC machine. However, for cases in which some freedom of orientation remains after conditions for machining in a single setup are satisfied, a second sort of optimality can also be considered: finding an orientation such that the cutting condition (relative orientation of the tool axis and the normal to the desired part surface) remains as constant, at some optimal angle, as possible. This second form of optimality is obtained by choosing an orientation (within the bounds of those allowing a single setup) in which the angle between the neutral axis of the milling tool and the area-weighted mean normal to the part surface, at a “central” point with a normal in that mean direction, is zero, or as small as possible. To find this solution, Gaussian maps (GMap) of the part surfaces to be machined and the machining surface of the tool are applied. To our knowledge, we are the first [1] who have picked up this Gauss’ idea to sculptured part surface orientation problem and who have developed the general approach to solve this important engineering problem [2]. Later a similar approach was claimed by Gan [3]. By means of GMaps of these surfaces, the problem of optimal workpiece orientation can be formulated as a geometric problem on a sphere. The GMap on a unit sphere finds wide application for orientation of workpiece for NC machining, for probing on coordinate measuring machines, etc. GMaps are useful for selecting the type of cutting tool, its path, workpiece fixturing, and the type of NC machine (its kinematic capabilities). The primary process application addressed is 3- and 4-axis NC milling, although the techniques presented may be applied to machines with more general articulation. The influence of tool geometry is also discussed and incorporated within a constrained orientation algorithm. This paper covers the following topics: a) the derivation of the equations of the GMap of the part surface to be machined and the machining surface of the tool; b) calculation of the parameters of the weighted normal to the part surface; c) optimal part orientation on the table of a multi-axis NC machine; d) introduction of a new type of GMap for a sculptured part surface—its expandedGMapE; and e) introduction of a new type of indicatrix of a sculptured part surface and a particular cutting tool–the indicatrix of machinability.

scholarly journals Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

2018 ◽  
Vol 178 ◽  
pp. 01016
Author(s):  
Irina Beşliu ◽  
Dumitru Amarandei ◽  
Delia Cerlincă
Keyword(s):  
Cutting Force ◽  
Tool Steel ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Tool ◽  
End Milling ◽  
Great Influence ◽  
Tool Geometry ◽  
Aisi D2 ◽  
Aisi D2 Tool Steel

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels.

scholarly journals Optimization of cutting tool geometry and machining parameters in turning process

2020 ◽  
Author(s):  
S. Saravanamurugan ◽  
B. Shyam Sundar ◽  
R. Sibi Pranav ◽  
A. Shanmugasundaram
Keyword(s):  
Cutting Tool ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Turning Process
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