scholarly journals The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers

2017 ◽  
Vol 91 (9-12) ◽  
pp. 3887-3898 ◽  
Author(s):  
D. Przestacki ◽  
T. Chwalczuk ◽  
S. Wojciechowski
Keyword(s):  
Cutting Forces ◽  
Chip Thickness ◽  
Uncut Chip Thickness ◽  
Minimum Uncut Chip Thickness ◽  
Laser Assisted Turning

scholarly journals Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1495
Author(s):  
Tongshun Liu ◽  
Kedong Zhang ◽  
Gang Wang ◽  
Chengdong Wang
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Minimum Uncut Chip Thickness ◽  
Cutting Force Coefficient ◽  
Milling Force Model

The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.

Determination of Minimum Uncut Chip Thickness in Micromachining

2009 ◽  
Vol 69-70 ◽  
pp. 408-412 ◽  
Author(s):  
Zhen Yu Shi ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Deformation ◽  
Geometric Model ◽  
Chip Thickness ◽  
Uncut Chip Thickness ◽  
Tool Edge Radius ◽  
Minimum Value ◽  
Edge Radius ◽  
Cutting Surface ◽  
Minimum Uncut Chip Thickness ◽  
Tool Edge

In micromachining, the uncut chip thickness is comparable to the tool edge radius, and chip won’t be generated if the uncut chip thickness is less than a critical value, besides that, the minimum uncut chip thickness affect many factors such as the cutting force, the chip’s modality, the cutting surface quality, etc. In this paper, a geometric model is developed to predict the minimum uncut chip thickness values. The model accounts for the theory that the critical condition of producing chip is when the friction of the surface deformation asperities is zero. Two situations when the minimum value is larger or smaller than the tool edge radius respectively to predict the minimum value are discussed. The influences of tool edge radius and material’s property on the minimum uncut chip thickness are taken into account.

Study on the machining process of micro V-shaped groove by using a revolving tip

2017 ◽  
Vol 232 (9) ◽  
pp. 1523-1537
Author(s):  
Bo Xue ◽  
Yongda Yan ◽  
Gaojie Ma ◽  
Zhenjiang Hu
Keyword(s):  
Cutting Forces ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Uncut Chip Thickness ◽  
Machined Surface ◽  
Advantages And Disadvantages

This paper proposed a machining method for micro V-shaped grooves, which was achieved by introducing the revolving trajectory on the basis of tip scratching process. By coordinating the revolving direction and the tip orientation, four kinds of revolving scratches were developed which had the revolving radii larger than the groove depths. It was found that there were two revolving scratches among these four being able to eliminate the side burrs and produce much smaller cutting forces during machining grooves compared to the traditional scratch, respectively named as the up-milling of face-forward and the down-milling of edge-forward. By considering the tip geometry in the traditional scratching process, the burr formation has been studied which was mainly affected by the effect of chip interference and the amount of uncut chip thickness. By analyzing the machining trajectory, the undeformed chip, the machined surface and the chip morphology, the reason why the up-milling of face-forward and the down-milling of edge-forward had good performances for machining V-grooves was elucidated in detail. Meanwhile, the differences between these two revolving scratches were discussed, and their advantages and disadvantages were also given.

Influence of the main cutting edge angle value on minimum uncut chip thickness during turning of C45 steel

2020 ◽  
Vol 57 ◽  
pp. 354-362 ◽  
Author(s):  
Tadeusz Mikołajczyk ◽  
Hubert Latos ◽  
Danil Yu. Pimenov ◽  
Tomasz Paczkowski ◽  
Munish Kumar Gupta ◽  
...  
Keyword(s):  
Chip Thickness ◽  
Cutting Edge ◽  
Uncut Chip Thickness ◽  
Edge Angle ◽  
Minimum Uncut Chip Thickness

Prediction of Ball End Milling Forces

1996 ◽  
Vol 118 (1) ◽  
pp. 95-103 ◽  
Author(s):  
G. Yu¨cesan ◽  
Y. Altıntas¸
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Analytic Representation ◽  
Rake Face ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Helical Flute ◽  
Milling Forces

Mechanics of milling with ball ended helical cutters are modeled. The model is based on the analytic representation of ball shaped helical flute geometry, and its rake and clearance surfaces. It is assumed that friction and pressure loads on the rake face are proportional to the uncut chip thickness area. The load on the flank contact face is concentrated on the in cut portion of the cutting edge. The pressure and friction coefficients are identified from a set of slot ball end milling tests at different feeds and axial depth of cuts, and are used to predict the cutting forces for various cutting conditions. The experimentally verified model accurately predicts the cutting forces in three Cartesian directions.

Dynamics of the Metal-Cutting Process

1965 ◽  
Vol 87 (4) ◽  
pp. 429-441 ◽  
Author(s):  
Paul Albrecht
Keyword(s):  
Dynamic Response ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Dynamic Properties ◽  
Chip Thickness ◽  
Cutting Process ◽  
Uncut Chip Thickness ◽  
Work Surface ◽  
Experimental Approaches ◽  
Inertia Forces

An investigation into the dynamics of the metal-cutting process has been carried out using analytical and experimental approaches. An exploratory analysis into the dynamic behavior of the cutting process revealed such dynamic properties as a loop response of the cutting forces caused by the waviness of the work surface. This finding indicates the possibility of unstable behavior of the cutting process in itself. It was possible to describe analytically the phase between the force response and fluctuations of uncut chip thickness for the case of a wavy work surface. Effects of the magnitude of the shear angle as well as of its fluctuations have been studied which make it possible to correlate the instability within the cutting process to the properties of the work material. Apart from the configuration of the cutting process, its physical properties, such as inertia forces in chip formation, have been introduced into the analysis because inertia forces, negligible at steady state, may grow significant if cutting conditions are fluctuating at higher frequencies. An experimental setup has been devised and built featuring a special design of a tool dynamometer particularly suitable for the measurement of dynamic response of the cutting forces. In the setup, a cutting tool activated by a hydraulic shaker is controlled in an average position by a feedback loop mechanism. This setup makes it possible to obtain a record of the dynamic response of cutting forces caused by the fluctuation of uncut chip thickness produced by an oscillating tool in the frequency range up to about 400 cps.

An Assessment, Definition, and Determination of the Minimum Uncut Chip Thickness of Microcutting and Impact on Machining New Powder Metallurgy Nickel-Based Superalloys

2011 ◽  
Author(s):  
Z. Y. Shi ◽  
Z. Q. Liu ◽  
Y. B. Guo
Keyword(s):  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Chip Thickness ◽  
Critical Value ◽  
Uncut Chip Thickness ◽  
Minimum Uncut Chip Thickness ◽  
Process Mechanics ◽  
Art Research ◽  
Future Work

The uncut chip thickness is comparable to the cutting edge radius in micromachining. If the uncut chip thickness is less than a critical value, there will be no chip formation. This critical value is termed as the minimum uncut chip thickness (MUCT). Although minimum uncut chip thickness has been well defined in orthogonal cutting, it is often poorly understood in practical complex turning and milling processes. This paper presents an analysis of the state-of-art research on minimum uncut chip thickness in precision micro-machining. The numerical and experimental methods to determine MUCT values and their effects on process mechanics and surface integrity in microcutting will be critically assessed in this paper. A set of definitions of minimum uncut chip thickness for three-dimensional turning and milling processes are presented. In addition, a detailed discussion on the characteristics of different methods to determine minimum uncut chip thickness and several unsolved problems are proposed for the future work.

scholarly journals A Slip-Line Field for Ploughing During Orthogonal Cutting

1998 ◽  
Vol 120 (4) ◽  
pp. 693-699 ◽  
Author(s):  
D. J. Waldorf ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Slip Line ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Great Promise ◽  
Uncut Chip Thickness ◽  
Workpiece Material ◽  
Line Field ◽  
Slip Line Field ◽  
Edge Radius

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and for negative rake angle orthogonal cutting. It incorporates the observed phenomena of a small stable build-up of material adhered to the edge and a raised prow of material formed ahead of the edge. The model shows how ploughing forces are related to cutter edge radius—a larger edge causing larger ploughing forces. A series of experiments were run on 6061-T6 aluminum using tools with different edge radii—including some exaggerated in size—and different levels of uncut chip thickness. Resulting force measurements match well to predictions using the proposed slip-line field. The results show great promise for understanding and quantifying the effects of edge radius and worn tool on cutting forces.

On Tool Instability During Machining

1991 ◽  
Author(s):  
C. Sahay ◽  
R. N. Dubey
Keyword(s):  
Cutting Force ◽  
Shear Deformation ◽  
Static Analysis ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Uncut Chip Thickness ◽  
Frictional Interaction ◽  
Machining System ◽  
The Relationship

Abstract The present paper describes the role of the tool in vibrations of a machining system. The cutting force has been assumed to be constant. The shear deformation of the tool is considered. The quasi-static analysis of the situation yields a maximum allowable uncut chip thickness, which shows how the frictional interaction at the tool face and the ratio of the components of cutting forces alter this value. The relationship also expresses the effect of tool dimensions and work material on the vibration of the tool.

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