3D metal removal simulation to determine uncut chip thickness, contact length, and surface finish in grinding

2012 ◽  
Vol 66 (9-12) ◽  
pp. 1715-1724 ◽  
Author(s):  
Abdalslam Darafon ◽  
Andrew Warkentin ◽  
Robert Bauer
Keyword(s):  
Surface Finish ◽  
Metal Removal ◽  
Chip Thickness ◽  
Contact Length ◽  
Uncut Chip Thickness

On the Surface Finish-Metal Removal Relationship in Precision Grinding

1973 ◽  
Vol 95 (3) ◽  
pp. 815-820 ◽  
Author(s):  
R. P. Lindsay
Keyword(s):  
Surface Finish ◽  
Metal Removal ◽  
Chip Thickness ◽  
Precision Grinding ◽  
Semiempirical Equation

A semiempirical equation representing the average chip thickness existing during grinding is presented. The scatter of surface finish data obtained using high and low wheel-speeds and wheel-work conformities, fine and coarse dressing procedures and various system spring stiffnesses is greatly reduced when plotted versus average chip thickness. Two metal removal regions, ploughing and cutting, are clearly defined by the finish-chip thickness graph. Altering machine variables in order to reduce the average chip thickness greatly improves surface finish in the cutting region. In the ploughing region, the finish improvements are smaller because the degree of ploughing and grooving of the workpiece possibly affects the measured finish.

Dynamic Chip Formation and its Significance to Machining Stability

1973 ◽  
Vol 187 (1) ◽  
pp. 273-283 ◽  
Author(s):  
D. F. Pearce ◽  
B. R. MacManus
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Chip Thickness ◽  
High Amplitude ◽  
Contact Length ◽  
Tangential Component ◽  
Shear Angle ◽  
Uncut Chip Thickness ◽  
Phase Measurements ◽  
Specific Contact

The physical processes of dynamic chip formation were examined experimentally using direct photographic techniques; motion in the cutting zone was frozen by synchronizing an intense stroboscopic flash to particular positions in the waveform of the cutting force. Measurements obtained under conditions of controlled vibratory machining gave instantaneous values of the uncut chip thickness, tool-chip contact length, effective shear angle and cutting force. At a given amplitude of uncut chip thickness the peak-to-peak variation of contact length was seen to attenuate with increasing frequency, an effect which was shown to be significant in causing relatively high amplitude shear angle oscillations. Amplitude and phase measurements of the tangential component of the cutting force on wave removal were directly related to the deduced waveform of specific contact length, a process yielding considerable predictability. Measurements were made of the damping inherent in the cutting process; results obtained by applying the techniques of impulse response testing showed the sensitivity of this damping to both the amplitude and the frequency of the variation of the uncut chip thickness. Internal damping resulting from the process of chip formation is not uniquely positive or negative but may vary, depending upon the combination of these parameters.

Kinematic simulation of the uncut chip thickness and surface finish using a reduced set of 3D grinding wheel measurements

2017 ◽  
Vol 49 ◽  
pp. 169-178 ◽  
Author(s):  
Andrew McDonald ◽  
Al-Mokhtar O. Mohamed ◽  
Andrew Warkentin ◽  
Robert J. Bauer
Keyword(s):  
Surface Finish ◽  
Chip Thickness ◽  
Grinding Wheel ◽  
Uncut Chip Thickness ◽  
Kinematic Simulation

Mechanism of Cutting Force and Surface Generation in Dynamic Milling

1991 ◽  
Vol 113 (2) ◽  
pp. 160-168 ◽  
Author(s):  
D. Montgomery ◽  
Y. Altintas
Keyword(s):  
Cutting Force ◽  
Surface Finish ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Dominant Frequency ◽  
Milling Process ◽  
Cutting Edge ◽  
Surface Generation ◽  
Uncut Chip Thickness ◽  
Improved Model

An improved model of the milling process is presented. The model proposes a method of determining cutting forces in five distinct regions where the cutting edge travels during dynamic milling. Trochoidal motion of the milling cutter is used in determining uncut chip thickness. The kinematics of the cutter and workpiece vibrations are modelled, which identifies the orientation and velocity direction of the cutting edge during dynamic cutting. The model allows the prediction of forces and surface finish under rigid or dynamic cutting conditions. The proposed mechanism of chip thickness, force and surface generation is proven with simulation and experimental results. It is found that when the tooth passing frequency is selected to be an integer ratio of a dominant frequency of tool-workpiece structure in milling imprint of vibrations on the surface finish is avoided.

Study on Unique Cutting Phenomena in Micro Endmilling - Mechanism and Possibility to Occur-

2009 ◽  
Vol 76-78 ◽  
pp. 508-513 ◽  
Author(s):  
Mitsuyoshi Nomura ◽  
Takahiro Kawashima ◽  
Takayuki Shibata ◽  
Yoshihiko Murakami ◽  
Masami Masuda ◽  
...  
Keyword(s):  
Tool Wear ◽  
Computer Simulations ◽  
Surface Finish ◽  
Chip Thickness ◽  
Cutting Process ◽  
Uncut Chip Thickness ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In micro endmilling, because of small uncut chip thickness comparable to the tool edge radius and low rigidity of tool, the cutting process must frequently transit between rubbing/ploughing and cutting, and it may deteriorate the machining stability, surface finish and tool wear. In this report, such unique cutting phenomena are investigated by modeling a mechanism, computer simulations and experiments. As a result, a possibility of the unique cutting phenomena proposed has been certified.

Dynamic Chip Formation and its Significance to Machining Stability

1973 ◽  
Vol 187 (1) ◽  
pp. 273-283 ◽  
Author(s):  
D. F. Pearce ◽  
B. R. MacManus
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Chip Thickness ◽  
High Amplitude ◽  
Contact Length ◽  
Tangential Component ◽  
Shear Angle ◽  
Uncut Chip Thickness ◽  
Phase Measurements ◽  
Specific Contact

The physical processes of dynamic chip formation were examined experimentally using direct photographic techniques; motion in the cutting zone was frozen by synchronizing an intense stroboscopic flash to particular positions in the waveform of the cutting force. Measurements obtained under conditions of controlled vibratory machining gave instantaneous values of the uncut chip thickness, tool-chip contact length, effective shear angle and cutting force. At a given amplitude of uncut chip thickness the peak-to-peak variation of contact length was seen to attenuate with increasing frequency, an effect which was shown to be significant in causing relatively high amplitude shear angle oscillations. Amplitude and phase measurements of the tangential component of the cutting force on wave removal were directly related to the deduced waveform of specific contact length, a process yielding considerable predictability. Measurements were made of the damping inherent in the cutting process; results obtained by applying the techniques of impulse response testing showed the sensitivity of this damping to both the amplitude and the frequency of the variation of the uncut chip thickness. Internal damping resulting from the process of chip formation is not uniquely positive or negative but may vary, depending upon the combination of these parameters.

Influence of Chip Curl on Tool-Chip Contact Length in High Speed Machining

2009 ◽  
Vol 626-627 ◽  
pp. 71-74 ◽  
Author(s):  
Xue Feng Bi ◽  
G. Sutter ◽  
Gautier List ◽  
Yong Xian Liu
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Contact Length ◽  
Radius Of Curvature ◽  
High Speed Machining ◽  
Uncut Chip Thickness ◽  
High Cutting Speed ◽  
Chip Formation Mechanism ◽  
The Relationship

The tool-chip contact length, as an important parameter controlling the geometry of tool crater wear and understanding chip formation mechanism, is widely investigated in machining. The aim of this paper is to study the influence of chip curl on tool-chip contact length by means of experimental observations with high cutting speed. The relationship between tool-chip contact length, chip radius of curvature and uncut chip thickness was investigated. Experimental results show the effect of increasing spiral chip radius on tool-chip contact length with low uncut chip thickness in high speed machining.

Effects of Alternative Metal Working Fluids Upon Tool Face Wear

2010 ◽  
Author(s):  
Lewis N. Payton ◽  
Prajwal Sripathi
Keyword(s):  
Surface Finish ◽  
Metal Cutting ◽  
Chip Thickness ◽  
Rake Angle ◽  
Industrial Applications ◽  
Factor Level ◽  
Nitrogen Gas ◽  
Uncut Chip Thickness ◽  
Tool Surface ◽  
Force Data

Orthogonal metal cutting allows the collection of force data in the laboratory in an analytical manner not practical during industrial applications. Orthogonal tube turning (OTT) allows the collection of force data at much higher speeds than the original methods used by Ernst and Merchant. An orthogonal tube turning apparatus was constructed and validated in order to study the effects of rake angle, uncut chip thickness and cutting environments on the tool forces and the wear of the tool face itself. Although there have been many studies which characterized the forces and the surface finish of the part machined, along with some version of tool life, this study is unique in that the wear of the tool face itself is characterized in a detailed analysis of variance (ANOVA) study. A widely utilized commercial water based product performed less well than either nitrogen gas or cold shop compressed air. Surface roughness of the tool was used to parameterize tool surface finish for cutting each factor level combination of the experiment.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

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