scholarly journals Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 698 ◽  
Author(s):  
Monkova ◽  
Monka ◽  
Sekerakova ◽  
Hruzik ◽  
Burecek ◽  
...  
Keyword(s):  
Chip Formation ◽  
Slow Rate ◽  
Material Removal ◽  
Cutting Tool ◽  
Tool Geometry ◽  
Formation Mechanisms ◽  
Machined Surface ◽  
Thermal Influence ◽  
Microstructure Of Material ◽  
Made In

In today’s unmanned productions systems, it is very important that the manufacturing processes are carried out efficiently and smoothly. Therefore, controlling chip formation becomes an essential issue to be dealt with. It can be said that the material removal from a workpiece using machining is based on the degradation of material cohesion made in a controlled manner. The aim of the study was to understand the chip formation mechanisms that can, during uncontrolled processes, result in the formation and propagation of microcracks on the machined surface and, as such, cause failure of a component during its operation. This article addresses some aspects of chip formation in the orthogonal and oblique slow-rate machining of EN 16MnCr5 steel. In order to avoid chip root deformation and its thermal influence on sample acquisition, that could cause the changes in the microstructure of material, a new reliable method for sample acquisition has been developed in this research. The results of the experiments have been statistically processed. The obtained dependencies have uncovered how the cutting tool geometry and cutting conditions influence a chip shape, temperature in cutting area, or microhardness according to Vickers in the area of shear angle.

Process Parameter and Cutting-Tool Geometry Study for Precision Face Turning of a Clock Dial

2011 ◽  
Vol 697-698 ◽  
pp. 125-128
Author(s):  
Shen Yung Lin ◽  
Y.H. Lin ◽  
M.S. Hsu
Keyword(s):  
Chip Formation ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Systematic Investigation ◽  
Process Parameter ◽  
Tool Geometry ◽  
Machined Surface ◽  
Related Quality

After the processing of a clock dial, the precision dimension and uniform distribution of the tool-trace pattern on the dial surface have a connection with luster image and attractiveness, which in turn would have an impact on the additional values and prices for a clock. Through a systematic investigation among the lathe structure, process parameter and cutting-tool geometry in advance, the total results indicated that the rigidity of the lathe structure and the precision of the slider movements are excellent and they had only a little effect on the surface-related quality for a dial face turning. Hence, the combination of process parameter and cutting-tool angle becomes more essential. End face turning simulation and experiment of a copper alloy were thus conducted in this paper, and the chip formation process and machined surface-related quality are investigated, respectively. The effects of cutting tool geometry and process parameter on the results of chip formation, surface rough, tool-trace pattern and luster uniformity are investigated, and these results are also compared with each other. The results show that when larger clearance and rake angles used in conjunction with a lower feed rate, no matter how much cutting speed was enhanced, the surface-related quality of a dial surface is not good. However, when these two larger angles used combined with a larger feed rate, the quality of a dial surface would slightly be improved. By using smaller clearance and rake angles along with the higher feed rate and cutting speed would obtain a better surface-related quality with uniform luster and attractiveness.

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.

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.

FEA-Based Comparative Investigation on High Speed Machining of Aluminum Alloys AA6061-T6 and AA7075-T651

2017 ◽  
Vol 261 ◽  
pp. 347-353 ◽  
Author(s):  
Walid Jomaa ◽  
Victor Songmene ◽  
Philippe Bocher ◽  
Augustin Gakwaya
Keyword(s):  
Aluminum Alloys ◽  
Residual Stresses ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Temperature ◽  
Numerical Data ◽  
Formation Mechanisms ◽  
High Speed Machining ◽  
Machined Surface ◽  
Initial Yield Stress

Independent research studies have shown notable dissimilarity in the machining behaviour of aluminum alloys AA6061−T6 and AA7075−T651 commonly used in automotive and aeronautical applications. The present work attempts to investigate this dissimilarity based on experimental and numerical data with a focus on chip formation and generated residual stresses under similar high−speed machining (HSM) conditions. The numerical data were calculated by a finite element modeling (FEM) developed using DeformTM 2D software. The results showed that both studied alloys exhibit different chip formation mechanisms and residual stress states at the machined surfaces. On one hand, the AA6061−T6 alloy generates continuous chips and tensile residual stresses whereas the AA7075−T651 alloy produces segmented chips and compressive residual stresses. FEM results showed that the AA6061−T6 alloy generates lower cutting temperature at the tool−chip interface along with higher equivalent total strains at the machined surface as compared to the AA7075−T651 alloy. Based on the experimental and numerical results, it was pointed out that the differences in terms of thermal conductivity and initial yield stress are the main reasons explaining the dissimilarity observed.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

Machining of Fused Silica Using Pulsed Laser Heating Assistance

2018 ◽  
Author(s):  
Huawei Song ◽  
Junfeng Xiao ◽  
Jialun Li ◽  
Jinqi Dan ◽  
Xiao Chen ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Material Removal ◽  
Cutting Tool ◽  
Local Heating ◽  
Fused Silica ◽  
Material Removal Mechanism ◽  
Machined Surface ◽  
Lower Tool ◽  
Pulsed Laser Heating ◽  
Conventional Machining

Fused silica is difficult to machine through conventional machining, mainly due to its high brittleness and strength, low fracture toughness and poor plastic deformation. This study was attempted to explore the machinability of fused silica with laser-assisted machining by heating workpiece through a pulse CO2 laser beam. During the LAM of fused silica, the bonding and wavelike texture on the machined surface indicated the behavior change of material deformation by the local heating in front of the cutting tool. The semi-continuous chips were obtained as an evidence of material removal mechanism which was a hybrid of quasi plastic deformation and brittle fracture. Moreover, the machinability of fused silica was evaluated. The experimental results demonstrated that considerable improvement in the machinability of fused silica was achieved such as better surface roughness, smaller cutting force as well as lower tool wear.

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.

Hard Turning: Chip Formation Mechanisms and Metallurgical Aspects

1999 ◽  
Vol 122 (3) ◽  
pp. 406-412 ◽  
Author(s):  
Ge´rard Poulachon ◽  
Alphonse L. Moisan
Keyword(s):  
Crack Initiation ◽  
Chip Formation ◽  
Hard Turning ◽  
Theoretical Study ◽  
Formation Mechanisms ◽  
Stick Slip ◽  
Chip Geometry ◽  
Hardness Values ◽  
Cutting Speeds ◽  
Made In

A 100Cr6 (AISI E52100) steel in the hardness range of 180 to 750 HV10 was machined. Quick stop tests were carried out at various hardness values to observe the different chip formation mechanisms. A limit was found between the shearing and cracking chip formation. Experiments on the selected steel at 750 HV10 were carried out at various cutting speeds and feed rates. The “saw tooth chips” obtained were examined geometrically and metallurgically on longitudinal midsections. A relationship has been established between the chip geometry and the cutting conditions. A theoretical study of the chip shape was made, in particular its thickness. The friction stick slip velocities, and the segment apparition frequency were calculated. Each stage of the chip formation could be observed on each micrograph of Q.S.T, especially the crack initiation. A discussion on the apparition of the thin white layers is also proposed. [S1087-1357(00)01502-1]

scholarly journals Optimisation of metal-cutting tool geometry based on chip formation requirement

2020 ◽  
Vol 843 ◽  
pp. 012022
Author(s):  
M A Korchuganova ◽  
Iurii Guskov ◽  
V R Ponurovskaya ◽  
A Syrbakov
Keyword(s):  
Chip Formation ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Tool Geometry ◽  
On Chip ◽  
Metal Cutting Tool

Hard Turning: Chip Formation Mechanisms and Metallurgical Aspects

1999 ◽  
Author(s):  
Gérard Poulachon ◽  
Alphonse L. Moisan
Keyword(s):  
Crack Initiation ◽  
Chip Formation ◽  
Hard Turning ◽  
Theoretical Study ◽  
Formation Mechanisms ◽  
Stick Slip ◽  
Chip Geometry ◽  
Hardness Values ◽  
Cutting Speeds ◽  
Made In

Abstract A 100Cr6 (AISI E52100) steel in the hardness range of 180 to 750 HV10 was machined. Quick stop tests were carried out at various hardness values to observe the different chip formation mechanisms. A limit was found between the shearing and cracking chip formation. Experiments on the selected steel at 750 HV10 were carried out at various cutting speeds and feed rates. The “saw tooth chips” obtained were examined geometrically and metallurgically on longitudinal midsections. A relationship has been established between the chip geometry and the cutting conditions. A theoretical study of the chip shape was made, in particular its thickness. The friction stick slip velocities, and the segment apparition frequency were calculated. Each stage of the chip formation could be observed on each micrograph of Q.S.T, especially the crack initiation. A discussion on the apparition of the thin white layers is also proposed.

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