Tool Wear Intensity in Correlation with Evolutionary Properties of Dynamic Cutting System

2021 ◽  
pp. 1155-1160
Author(s):  
V. L. Zakovorotny ◽  
V. P. Lapshin ◽  
V. E. Gvindjilia
Keyword(s):  
Tool Wear ◽  
Wear Intensity ◽  
Cutting System

Synergetic Concept of Software Control of Machining Processes on Metal-Cutting Machines

2021 ◽  
pp. 24-36
Author(s):  
V.L. Zakovorotny ◽  
V.E. Gvindzhiliya
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Wear Testing ◽  
External Control ◽  
Machining Processes ◽  
Cutting Zone ◽  
Output Characteristics ◽  
The Cost ◽  
And Control ◽  
Cutting System

High precision metal-cutting machines ensure that the programmed machine actuator trajectories correspond to the real ones. For lathes these are the trajectories of the longitudinal and transverse calipers of the system, as well as the spindle. The purpose of processing is to produce parts of a given quality while minimizing the manufacturing costs. The condition of the dynamic cutting system, determined by the trajectories of forces and deformations, affects the quality indicators of parts and the cutting efficiency, which depends on the intensity of tool wear. The properties of the system change depending on the phase trajectory of the power of irreversible transformations of the energy supplied to the cutting zone by the work performed. Their changes related with the evolution of the parameters of the dynamic link formed by cutting are manifested in the development of tool wear and changes in the quality of the part. Thus, the power of irreversible energy transformations is one of the internal factors causing changes in the output characteristics of processing and the state of the process. In this regard, when processing on machine tools, there is a problem of synergistic coordination of external control (for example, the CNC program) with internal one, the source of which is the irreversible transformation of the energy supplied to the cutting zone. The article considers the problem of synergetic coordination of external and internal controls during cutting process, the solution of which will allow increasing the efficiency of processing on CNC machines. A mathematical model of a controlled dynamic cutting system and control algorithms are proposed to improve the efficiency of processing parts of a given quality while minimizing the intensity of tool wear. Testing of the developed algorithms has shown that their use reduces the cost of manufacturing parts by 1.2.

A New Approach to Blade Design With Constant Rake and Relief Angles for Face-Hobbing of Bevel Gears

2015 ◽  
Vol 138 (3) ◽  
Author(s):  
Mohsen Habibi ◽  
Zezhong Chevy Chen
Keyword(s):  
Tool Wear ◽  
Machine Tool ◽  
Computer Aided Design ◽  
Cutting Edge ◽  
Wear Characteristics ◽  
Bevel Gears ◽  
Cutting Velocity ◽  
Productive Process ◽  
Aided Design ◽  
Cutting System

Face-hobbing is a productive process to manufacture bevel and hypoid gears. Due to the complexity of face-hobbing, few research works have been conducted on this process. In face-hobbing, the cutting velocity along the cutting edge varies because of the intricate geometry of the cutting system and the machine tool kinematics. Due to the varying cutting velocity and the specific cutting system geometry, working relief and rake angles change along the cutting edge and have large variations at the corner which cause the local tool wear. In this paper, a new method to design cutting blades is proposed by changing the geometry of the rake and relief surfaces to avoid those large variations while the cutting edge is kept unchanged. In the proposed method, the working rake and relief angles are kept constant along the cutting edge by considering the varying cutting velocity and the machine tool kinematics. By applying the proposed method to design the blades, the tool wear characteristics are improved especially at the corner. In addition, in this paper, complete mathematical representations of the cutting system are presented. The working rake and relief angles are measured on the computer-aided design (CAD) model of the proposed and conventional blades and compared with each other. The results show that, unlike the conventional blade, in case of the proposed blade, the working rake and relief angles remain constant along the cutting edge. In addition, in order to validate the better tool wear characteristics of the proposed blade, finite element (FE) machining simulations are conducted on both the proposed and conventional blades. The results show improvements in the tool wear characteristics of the proposed blade in comparison with the conventional one.

Lapping Tool Wearing Uniformly in Machining Blind Hole of Workpiece in Manufacturing System

2012 ◽  
Vol 252 ◽  
pp. 310-314
Author(s):  
Jian Dong Yang ◽  
Chuang Liu ◽  
Hui Yan
Keyword(s):  
Tool Wear ◽  
Density Distribution ◽  
Intensity Distribution ◽  
Manufacturing Process ◽  
Manufacturing System ◽  
Wear Intensity ◽  
Machining Time ◽  
Shape Accuracy ◽  
Original Surface ◽  
Tool Surface

This paper proposes a new method of controlling abrasives density distribution on the machining surface of a lapping tool making full use of controllability of abrasives density distribution in solid abrasive lapping, based on the present actual problems in solid abrasive lapping blind holes in manufacturing process. This method makes the abrasives density distribution on the lapping tool surface fit the wear intensity distribution of lapping tool, which makes the lapping tool wear uniformly in this manufacturing process, does not lose its original surface accuracy, ensures shape accuracy of the machined holes of the workpiece, also avoids the trouble of dressing lapping tools, reduces auxiliary machining time, improves machining efficiencies, reduces the consumption of abrasives and reduces machining costs of the manufacturing process.

Influence of Cutting Dynamic on the Selection of the Technological Regimes to Ensure Minimal Wear of Cutting Tools

2020 ◽  
Vol 22 (4) ◽  
pp. 54-70
Author(s):  
Vilor Zakovorotny ◽  
◽  
Valery Gvindjiliya ◽  
Keyword(s):  
Wear Resistance ◽  
Wear Rate ◽  
Tool Wear ◽  
Dynamic System ◽  
Heat Production ◽  
Dynamic Properties ◽  
Cutting Process ◽  
Tool Wear Rate ◽  
Cutting Path ◽  
Cutting System

Introduction. The intensity of tool wear, as an increment of wear to the cutting path, characterizes one of the important processing indicators. It is used in the development of algorithms for controlling the cutting process, including the calculation of trajectories in CNC machines. As the cutting speed increases, there is a value at which the wear rate is minimal. It corresponds to the optimal value of heat production in the cutting zone, that is, the power of irreversible transformations of the energy supplied to cutting. Heat production depends on the dynamic system parameters that change along the tool path. In this regard, at the initial stage and during processing, it is necessary to coordinate the control with the properties of the dynamic cutting system. Subject. The paper offers a study and analysis of the relationship between the tool wear rate and the dynamic properties of the cutting process, and on this basis, the definition of technological modes in which the wear rate is minimal. The purpose of this work is to study the dependence of the tool wear rate on the initial and changing dynamic properties of processing along the path, and to create on this basis methods for matching technological modes with the current cutting dynamics to reduce the wear rate. Method and methodology of the work. In this paper, experimental and analytical methods are used to study the evolutionary changes in the properties of the system in relation to the development of tool wear. The developed mathematical models of the cutting system are presented, which differ from the known ones in that the power of irreversible energy transformations of the mechanical system in the interface of the back faces of the tool with the workpiece is additionally modeled. The dependence of the wear rate on the power of irreversible transformations, that is, on a given time interval in the increment of wear, is given. This takes into account the dependence of wear on the dynamic properties of the cutting system, including during its evolution. Results and discussions. It is shown that the properties of evolution are sensitive to small variations in the parameters of the dynamical system. These variations make significant changes in the wear rate. The paper reveals the dependence of wear on the properties of a dynamic system, that is, on its parameters, technological modes, beats, and other perturbations. Conclusions. The disclosure of the dependence of wear resistance on the dynamic properties of the cutting process characterizes new ideas about the factors that affect wear resistance.

Machining Setting Optimization for Formate® Face-Hobbing of Bevel Gears With the Cutting Force and Tool Wear Constraints

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Mohsen Habibi ◽  
Zezhong Chevy Chen
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Experimental Tests ◽  
Wear Depth ◽  
Crater Wear ◽  
Machining Time ◽  
Integrated Method ◽  
Bevel Gears ◽  
Cutting System ◽  
Small Elements

Trial and error experiments are the dominant approaches to select machining settings and also cutting system design in face-hobbing of bevel gears. These time-consuming experimental tests impose undesired costs to industries. In the present paper, an integrated method is proposed to find optimum machining settings in face-hobbing based on minimum machining time and allowable cutting force and tool wear. Cutting blades in face-hobbing are converted to many infinitesimal oblique elements along the cutting edge, and the cutting forces and the tool wear are predicted on all these small elements. The constructed optimization problem seeks a face-hobbing scenario with minimum plunge time which meets the cutting force or crater wear depth constraints. The proposed method is applied in two case studies successfully to show the capability of the approach.

Study of Impact of Tool Wear on Stable Region for Die Steel Cutting Process

2013 ◽  
Vol 589-590 ◽  
pp. 204-208
Author(s):  
Cai Xu Yue ◽  
Da Qu ◽  
Yong Heng Yang ◽  
Fei Liu ◽  
Hui Zhe Feng
Keyword(s):  
Tool Wear ◽  
Evaluation Model ◽  
Cutting Speed ◽  
Stability Domain ◽  
Cutting Process ◽  
System Stability ◽  
Stable Region ◽  
Analysis Model ◽  
Root Locus ◽  
Cutting System

The stability of the process systems has an obvious impact on the cutting quality, seeking cutting process stability region is an important aspect of the cutting mechanism. In this paper, establishing cutting process dynamic analysis model is based on the tool wear and creating the evaluation model about the influence of tool wear on the cutting system stability by power spectral RMS method. Root locus plot of non-uniform load distribution is obtained and the minimum stiffness ratio in the root locus plot is determined. So as to arrive the limit plot in different tool wear cutting system stability domain and determine the flank wear limit in the stable cutting quantitatively and offer the parameter of design and evaluation indicators to cutting system. The results found that with the increase in cutting speed and tool wear intensifies, the system stability is sharp in decline and tool wear is more intense. Obtaining limit diagram of cutting stability domain is suitable for providing a theoretical basis for processing in the different tool wear conditions.

scholarly journals Sustainability and tool wear of titanium alloy thread cutting in dry and cryogenic conditions

2021 ◽  
Author(s):  
Anna Zawada-Tomkiewicz ◽  
Łukasz Żurawski ◽  
Dariusz Tomkiewicz ◽  
Filip Szafraniec
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Pure Titanium ◽  
Wear Intensity ◽  
Cryogenic Cooling ◽  
Thread Cutting ◽  
Wear Process ◽  
Development Models ◽  
Cutting Zone ◽  
Edge Reduction

AbstractThe article is devoted to the study of the effect of cryogenic cooling on the tool wear in thread turning tests. The tool wear and its influence on the thread accuracy were investigated. Two different grades of titanium alloys were used for comparative purposes. The excellent performance characteristics of titanium alloys pose machining problems, causing high unit forces at the edge of the tool leading to chipping and premature tool failure. In turn, the low thermal conductivity of pure titanium affects the heat distribution in the cutting zone. The heat is not absorbed by the material being machined but accumulates in the tool, causing an increase in diffusion and chemical wear. The results of cutting tests using liquid nitrogen showed lower values of wear on the major and minor tool flank. The edge reduction of the tool was also significantly less during cryogenic machining. The analysis of the formation of wear marks and the blade wear mechanisms was carried out for the tool rake face. The tests were carried out using the SEM method and confirmed by EDS analyses. In order to compare the course of tool wear over time, a mathematical model was developed, which results from the course of phenomena during cutting. It consists of two complementary equations. The first equation is characteristic for the first cutting phase and results from the loads imposed on the blade and aims at thermodynamic equilibrium. It is a period of stable tool operation and constant wear intensity. The second equation concerns crossing the equilibrium point followed by the process of accumulation of elementary wear phenomena. These phenomena accumulate until the blade is completely worn-out. The use of blade wear development models to determine the expected blade life allowed to confirm the beneficial effect of cryogenic cooling on the course of the blade wear process when cutting threads for two different titanium alloys.

USE OF THE THEORY OF SIMILARITY IN THE STUDY OF CUTTING TOOL WEAR

Tribologia ◽  
2018 ◽  
Vol 277 (1) ◽  
pp. 7-10
Author(s):  
Vyacheslav F. BEZYAZYCHNY ◽  
Marian SZCZEREK ◽  
V.V. NEPOMILUEV ◽  
Z.W. KISELEV
Keyword(s):  
Mechanical Properties ◽  
Tool Wear ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Wear Intensity ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Dimensionless Numbers ◽  
Tool Materials ◽  
Cutting Tool Wear

The paper highlights the methods to define wear intensity of cutting tools using the theory of similarity. The dimensionless numbers of the cutting procedures, which are necessary in calculating cutting tool wear intensity, are defined with regard to the cutting conditions, cutting tool geometry, and the physico-mechanical properties of the work stock and the tool materials.

Technical Resource of the Cutting Wedge is the Foundation of the Machining Regime Determination

2020 ◽  
Vol 10 (2) ◽  
pp. 1-17 ◽  
Author(s):  
Viktor P. Astakhov ◽  
Stanislav V. Shvets
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Tool Wear ◽  
Work Done ◽  
Cutting System ◽  
Small Tool

This article argues that cutting tool wear is not just a particular case of wear found in general machinery because the whole amount of energy required for cutting is transmitted through relatively small tool-chip and tool-workpiece interfaces causing extremely high contact temperatures and pressures. This article discusses a considerably different approach to the determination of the cutting speed based upon the energy passing through the cutting wedge. Moreover, it discusses that, for a given tool material/geometry, there is a limited amount of such energy that the cutting wedge can sustain before reaching the criterion of tool life. This limit is considered as the technical resource of the cutting tool. The article establishes and verifies the existence of the detect correlation between the works done in the cutting system and in tool wear. Based on this finding, the equations to calculate the cutting speed for a chosen tool life and/or the tool life for a chosen cutting speed are proposed. The concept of the technical resource of the cutting wedge is introduced as the total amount of work done before it fails.

Autoregressive Spectrum Analysis of Vibration and Condition Monitoring of Self-Propelled Rotary Tool

2007 ◽  
Vol 329 ◽  
pp. 743-748
Author(s):  
Wangs Shen Hao ◽  
Xun Sheng Zhu ◽  
Biao Jun Tian ◽  
M.R. Chi
Keyword(s):  
Time Series ◽  
Tool Wear ◽  
High Speed ◽  
Vibration Characteristic ◽  
High Speed Cutting ◽  
Rotary Tool ◽  
General Improvement ◽  
Sound Foundation ◽  
Machining Operations ◽  
Cutting System

Self-propelled rotary tools are being rediscovered for their applications in machining of ‘difficult-to-machine’ materials or for general improvement in the productivity of machining operations. The vibration characteristic and the occurrence of chatter during high speed cutting will induce the deterioration of precision and machining surface, tool wear and tool life. This paper deals with the identification of the vibration in SPRT cutting system with AR time series model. The experiment and deduction method provide a sound foundation for improving the structure with high antivibration strength, which could reduce the relative vibration between tool and workpiece in the alloweable scope.

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