scholarly journals Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5524
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Yongxiang Wu
Keyword(s):  
Simulation Model ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Interface Layer ◽  
Machining Process ◽  
Two Dimensional ◽  
Al Composite ◽  
The Matrix ◽  
Cutting Path

In this paper, a two-dimensional orthogonal cutting simulation model of SiCp/Al composite was established. The geometry and material constitutive model of the particle, the matrix, and the interface layer have been modeled respectively. In view of the distribution of the particles in the matrix, this paper proposed respectively a two-dimensional particle random distribution to simulate particles randomly distributed in the matrix. Then, the cutting state of SiC reinforced particles was analyzed, the novel approach was adopted the geometric shapes of SiC particles in this study is taken as an oval shape. Three different locations of SiC particle relative to the cutting tool path were simulated to analyze the cutting state such as particle removal. The interface layer was introduced to the case that the particle was on the cutting path to study the influence on the stress and strain transfer. Through the post-processing of simulation results, the influence of interface property on the composite reinforcement effect was studied quantificationally. Finally, the cutting process of SiCp/Al composite material was simulated. This paper studied the influence on the machined surface morphology, chip morphology, stress distribution, and cutting force of many factors of the cutting speed and the cutting thickness. The single factor orthogonal cutting experiment was designed the influence of cutting speed and feed rate on the cutting force. The cutting force results of the experiment and the simulation were compared through the deviation analysis, which verified the simulation model.

scholarly journals Experimental study on cutting parameters and machining paths of SiCp/Al composite thin-walled workpieces

2020 ◽  
Vol 29 ◽  
pp. 2633366X2094252
Author(s):  
Yunan Liu ◽  
Shutao Huang ◽  
Keru Jiao ◽  
Lifu Xu
Keyword(s):  
Cutting Force ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Machining Process ◽  
Cutting Depth ◽  
Processing Efficiency ◽  
Al Composite ◽  
Edge Defects ◽  
Thin Walled

Thin-walled workpieces of silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites with outstanding properties have been widely applied in many fields, such as automobile, weapons, and aerospace. However, the thin-walled workpieces exhibit poor rigidity, large yield ratio, and easily deform under the cutting force and cutting heat during the machining process. Herein, in order to improve the processing efficiency and precision of higher volume fraction SiCp/Al composite thin-walled workpieces, the influence of different high-speed milling parameters and machining paths on the edge defects is analyzed. The results reveal that the cutting force initially increased and then decreased with the cutting speed. Besides, the cutting force steadily increased with radial cutting depth and feed per tooth, but the influence of feed per tooth is less than radial cutting depth. After up-milling cut-in and cut-out processing and down-milling cut-out processing, the cut-in end of the workpiece exhibited higher breakage and obvious edge defects. However, the workpiece edges remained intact after down-milling cut-in processing. In conclusion, a higher cutting speed, a smaller radial cutting depth, and moderate feed per tooth are required to decrease the cutting force during the milling of SiCp/Al composite thin-walled workpiece. Furthermore, down-milling cut-in processing mode can reduce the edge defects and improve the processing efficiency and precision of the workpiece.

scholarly journals Serrated Chips Formation in Micro Orthogonal Cutting of Ti6Al4V Alloys with Equiaxial and Martensitic Microstructures

Micromachines ◽  
2019 ◽  
Vol 10 (3) ◽  
pp. 197 ◽  
Author(s):  
ZeJia Zhao ◽  
Suet To ◽  
ZhuoXuan Zhuang
Keyword(s):  
Cutting Force ◽  
Unit Length ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Orthogonal Machining ◽  
Large Yield ◽  
Power Spectral ◽  
Straight Line ◽  
Serrated Chips ◽  
Electropulsing Treatment

The formation of serrated chips is an important feature during machining of difficult-to-cut materials, such as titanium alloy, nickel based alloy, and some steels. In this study, Ti6Al4V alloys with equiaxial and acicular martensitic microstructures were adopted to analyze the effects of material structures on the formation of serrated chips in straight line micro orthogonal machining. The martensitic alloy was obtained using highly efficient electropulsing treatment (EPT) followed by water quenching. The results showed that serrated chips could be formed on both Ti6Al4V alloys, however the chip features varied with material microstructures. The number of chip segments per unit length of the alloy with martensite was more than that of the equiaxial alloy due to poor ductility. Besides, the average cutting and thrust forces were about 8.41 and 4.53 N, respectively, for the equiaxed Ti6Al4V alloys, which were consistently lower than those with a martensitic structure. The high cutting force of martensitic alloy is because of the large yield stress required to overcome plastic deformation, and this force is also significantly affected by the orientations of the martensite. Power spectral density (PSD) analyses indicated that the characteristic frequency of cutting force variation of the equiaxed alloy ranged from 100 to 200 Hz, while it ranged from 200 to 400 Hz for workpieces with martensites, which was supposedly due to the formation of serrated chips during the machining process.

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.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

Study on Determination of Friction Model at the Tool-Chip Interface of Titanium Alloy Ti6Al4V Based on Orthogonal Cutting

2011 ◽  
Vol 117-119 ◽  
pp. 1788-1791
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Friction Model ◽  
Carbide Tool ◽  
Orthogonal Turning ◽  
Titanium Alloy Ti6al4v

It is necessary for cutting simulation to determine the friction model at the tool-chip interface suitable for metal cutting process. Cutting force experiments in orthogonal turning titanium alloy TI6AL4V are carried out with cement carbide tool KW10. The Coulomb frictions at the tool-chip interface are calculated based on measured cutting force, and the friction model is regressed, where cutting speed and feed rate are presented.

scholarly journals Effect of Machining Parameters on Cutting Force and Surface Roughness during Dry Turning of Al6061/Zrb2alumium Matrix Composite

2019 ◽  
Vol 9 (2) ◽  
pp. 1422-1424
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Matrix Composite ◽  
Cutting Speed ◽  
Stir Casting ◽  
Machining Parameters ◽  
Al 6061 ◽  
The Matrix ◽  
In Situ Reactions

This paper shows that the outcome of analysis by the machining of Al-6061–ZrB2.which has done through in-situ reactions. Al 6061 alloy is reinforced with zirconium diboride by stir casting method.The reaction of K2ZrF6 and KBF4 will form ZrB2 at a temperature of 860°C and a holding time of 45 minutes using in-situ reaction. The molten metal matrix composite is poured into the pre-heated die with diameter of 50mm and length 500 mm. Influence of reinforcement ratio of 0, 5 and 10 wt% of ZrB2 on machinability are examined. By the turning operation cutting force was reduced, when the cutting speed has increased. The increment in ZrB2 particles within the matrix decreases the cutting force. Surface roughness is enhanced due to improvement in surface roughness and cutting speed deteriorated because of more addition of reinforcement

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

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