scholarly journals The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2926 ◽  
Author(s):  
Krzysztof Dudzik ◽  
Wojciech Labuda
Keyword(s):  
Acoustic Emission ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Radial Force ◽  
Diagnostic Methods ◽  
304L Stainless Steel ◽  
Turning Process ◽  
Physical Acoustics ◽  
Machined Surface ◽  
Feed Force

Ensuring optimal turning conditions has a huge impact on the quality and properties of the machined surface. The condition of the cutting tool is one of the factors to achieve this goal. In order to control its wear during the turning process, monitoring was used. In this study, the acoustic emission method and measure of cutting forces during turning were used for monitoring that process. The research was carried out on a universal lathe center (CU500MRD type) using a Kistler dynamometer with assembled removable insert CCET09T302R-MF by DIJET Industrial CO., LTD. A dynamometer allows to measure forces Fx (radial force), Fy (feed force) and Fz (cutting force). The turning process was performed on a shaft with 60 mm diameter made of 304L stainless steel. The AE research was carried at Physical Acoustics Corporation with the kit that includes: recorder USB AE Node, preamplifier, AE-sensor VS 150M and computer with dedicated software used for recording and analyzing AE data. The aim of this paper is to compare selected diagnostic methods: acoustic emission and cutting forces measurement for monitoring wear of cutting tool edge. Analysis of the research results showed that both selected methods of monitoring the turning process allowed the determination of the beginning of the tool damage process.

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

Finite Element Analysis of Tool Stresses, Temperature and Prediction of Cutting Forces in Turning Process

2017 ◽  
Vol 261 ◽  
pp. 354-361 ◽  
Author(s):  
Martin Necpal ◽  
Peter Pokorný ◽  
Marcel Kuruc
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Element Model ◽  
Turning Process ◽  
Element Analysis ◽  
Tool Stresses ◽  
Chip Separation ◽  
Carbide Insert

The paper presents the simulation model of turning the process of C45 non-alloy steel with a tool made of carbide insert. A 3D final element model used a lagrangian incremental type and re-meshing chip separation criterion was experimentally verified by measure cutting forces using piezoelectric dynamometer. In addition, stresses and temperature in the tooltip were predicted and examine. This work could investigate failure the tooltip, which would be great interest to predict wear and damage of cutting tool.

scholarly journals The Possibility of Monitoring Forces during Turning Process of Shafts Made of AW-7020 Aluminium Alloy for Variable Treatment Conditions

2020 ◽  
Vol 15 ◽  
Keyword(s):  
Aluminium Alloy ◽  
Cutting Speed ◽  
Radial Force ◽  
Cover Plate ◽  
Depth Of Cut ◽  
Turning Process ◽  
Treatment Conditions ◽  
Feed Force ◽  
Orthogonal Components ◽  
Cutting Insert

The article presents the research results referring to the analysis of the influence of cuttingparameters on value of cutting forces during turning pins of shaft. For the monitoring of forces during lathingprocess used Kistler dynamometer. The dynamometer is used for dynamic and quasistatic measurements of the3 orthogonal components of any forces acting on the cover plate (Fx - radial force, Fy - feed force andFz - cutting force). The turning process was carried out on a universal CU500MRD/1000 centre lathe. Theresearch was performed on a shaft made of 7020 aluminium alloy. Chemical composition of aluminium alloywas measured by Solaris-ccd plus optical spectrometer. The finishing turning process was carried out by cuttingtool with CCGT09T302-DL removable insert by Duracarb. During turning the following machining parameterswere used: cutting speed, feed and depth of cut. The goal of the paper was to define the influence of treatmentconditions on values of forces during turning process, and thus monitoring the wear of the cutting insert.

ANALYSIS OF CUTTING FORCES WHILE TURNING DIFFERENT MATERIAL

2020 ◽  
Vol 15 (4) ◽  
Author(s):  
Krishna Kumar M ◽  
Sangaravadivel P
Keyword(s):  
Cutting Force ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Tool Material ◽  
Radial Force ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Force

The measurement of cutting forces in metal cutting is essential to estimate the power requirements, to design the cutting tool and to analyze machining process for different work and tool material combination. Although cutting forces can be measured by different methods, the measurement of cutting forces by a suitable dynamometer is widely used in industrial practice. Mechanical and strain gauge dynamometer are most widely used for measuring forces in metal cutting. The principle of all dynamometers is based on the measurement of deflections or strain produced from the dynamometer structure from the action of cutting force. In this project, a dynamometer is used to measure cutting force, feed force and radial force by using strain gauge accelerometer while turning different material in lathe. The dynamometer is a 500kg force 3- component system. As the tool comes in contact with the work piece the various forces developed are captured and transformed into numerical form system. In this project three forces of different materials such as aluminum, mild steel, brass, copper have been noted down. The forces on these materials with variation in speed and depth of cut are studied. Graphs are drawn on how these forces vary due to variation in speed.

Experimental Investigations into Machining of FRP Material

2016 ◽  
Vol 836-837 ◽  
pp. 29-35
Author(s):  
Pavel Zeman ◽  
Petr Kolar ◽  
Petr Masek
Keyword(s):  
Surface Quality ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cellulose Fibre ◽  
Experimental Investigations ◽  
Tool Geometry ◽  
Machined Surface ◽  
Milling Operations ◽  
Machined Surface Quality

Machining of fibre-reinforced thermosets is becoming a very popular technology today. Nevertheless, machinability of these materials is rather different from conventional materials such as metals since hard and abrasive fibres are combined with relatively soft resin with low glass transition temperature. Special attention has to be given to workpiece quality because delamination and burning of machined surface can occur. An experimental investigation into machinability of a polymeric and cellulose fibre-reinforced resin material was carried out. Milling operations were inspected with respect to process temperature, cutting forces and machined surface quality. The effect of cutting conditions on the mentioned aspects was determined. Standard and tailored cutting tools were used in the investigation. It was observed that surface quality is strongly dependent on tool geometry, milling strategy, fibre orientation and feed. On the other hand, cutting forces are relatively low and dependent on tool geometry and feed. The modified cutting tool with more positive tool geometry showed better results compared to the conventional one.

scholarly journals EFFECT OF CUTTING PARAMETERS ON CUTTING FORCES IN TURNING OF CPM 10V STEEL

2021 ◽  
Vol 24 (2) ◽  
pp. 5-8
Author(s):  
Anđelko Aleksić ◽  
◽  
Milenko Sekulić ◽  
Marin Gostimirović ◽  
Dragan Rodić ◽  
...  
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Physical And Mechanical Properties ◽  
Cutting Parameters ◽  
Radial Force ◽  
Depth Of Cut ◽  
Feed Force ◽  
Cnc Lathe ◽  
Method Analysis

The objective of this paper is to investigate the effect of cutting parameters on cutting forces during turning of CPM 10V steel with coated cutting tool. Machining of CPM 10V steel and finding a suitable tool is very challenging due to its physical and mechanical properties, especially since the machining of this material has not been extensively researched. The experiments were carried out using an Index GU -600 CNC lathe and the cutting forces were measured in process. A three-factorial three-level experimental design was used for the experiments. Statistical method analysis of variance (ANOVA) is applied to study the effects of cutting speed, feed rate, and depth of cut on cutting forces. The results of this study show that depth of cut has the most significant effect on main force and radial force, while feed rate and cutting speed have the most significant effect on feed force. The developed model can be used in the machining industry to predict and analyze cutting parameters for optimal cutting forces.

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.

scholarly journals Analysis of Surface Roughness and Cutting Forces in Hard Turning of 42CrMo4 Steel using Taguchi and RSM Method

Mechanika ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 231-241 ◽  
Author(s):  
Mustafa ÖZDEMİR ◽  
Mehmet Tuncay KAYA ◽  
Hamza Kemal AKYILDIZ
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tangential Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Feed Force

In this study, effects of cutting speed (V), feed rate (f), depth of cut (a) and tool tip radius (R) on  surface roughness (Ra, Rz, and Rt) and cutting forces (radial force (Fx), tangential force (Fy), and feed force (Fz)) in hard finish turning processes of hardened 42CrMo4 (52 HRC) material was investigated experimentally. Taguchi’s mixed level parameter design (L18) is used for the experimental design (2x1,3x3). The signal-to-noise ratio (S/N) was used in the evaluation of test results.  By using Taguchi method, cutting parameters giving optimum surface roughness and cutting forces were determined. Regression analyses are applied to predict surface roughness and cutting forces. Analysis of variance (ANOVA) is used to determine the effects of the machining parameters on surface roughness and cutting forces. According to ANOVA analysis, the most important cutting parameters were found to be feed rate for surface roughness and depth of cut among cutting forces.  By conducting validation experiments, optimization was seen to be applied successfully.

FEM SIMULATION ASSESSMENT OF MACHINING TITANIUM GRADE 2 USING TEXTURED TOOL

2021 ◽  
pp. 2150080
Author(s):  
RIMA SINGHA ROY ◽  
KALIPADA MAITY
Keyword(s):  
Effective Stress ◽  
Cutting Forces ◽  
Numerical Study ◽  
Effective Strain ◽  
Cutting Temperature ◽  
Fem Simulation ◽  
Element Model ◽  
Radial Force ◽  
Feed Force ◽  
Titanium Grade

This work focuses on the 3D numerical investigation of machinability criteria using textured tools for the dry machining of titanium grade 2. For the development of the 3D finite element model, DEFORM-3D (version 10.1) software was used. Dimple patterns were created nearer to the cutting edge region on the rake face of carbide inserts so as to predict their effect and investigate the machinability criteria. Comparison of dimple-textured tool was being made with a conventional tool based on the cutting forces ([Formula: see text], [Formula: see text] and [Formula: see text], cutting temperature, tool wear, effective stress and effective strain. The numerical study revealed that the dimple-patterned tool improved the machinability of titanium grade 2. The cutting forces (tangential cutting force, feed force and radial force) reduced while machining with a dimple-patterned tool as compared to the conventional nontextured tool. There was an enhancement of tool life and a decrease in effective stress and effective strain while dry turning grade-2 titanium alloy using the textured tool.

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