A hybrid model for force prediction in orthogonal cutting with chamfered tools considering size and edge effect

2020 ◽  
Vol 110 (5-6) ◽  
pp. 1367-1384
Author(s):  
Jian Weng ◽  
Kejia Zhuang ◽  
Jinming Zhou ◽  
Han Ding
Keyword(s):  
Hybrid Model ◽  
Edge Effect ◽  
Orthogonal Cutting ◽  
Force Prediction ◽  
Chamfered Tools

Instantaneous milling force prediction and valuation of end milling based on friction angle in orthogonal cutting

2021 ◽  
Author(s):  
Hongjian Ding ◽  
Bin Zou ◽  
Jinzhao Yang ◽  
Juncheng Wang ◽  
Chuanzhen Huang ◽  
...  
Keyword(s):  
End Milling ◽  
Orthogonal Cutting ◽  
Friction Angle ◽  
Milling Force ◽  
Force Prediction

Microscopic mechanism based force prediction in orthogonal cutting of unidirectional CFRP

2015 ◽  
Vol 79 (5-8) ◽  
pp. 1209-1219 ◽  
Author(s):  
Zhenchao Qi ◽  
Kaifu Zhang ◽  
Hui Cheng ◽  
Dong Wang ◽  
Qingxun Meng
Keyword(s):  
Orthogonal Cutting ◽  
Microscopic Mechanism ◽  
Force Prediction

scholarly journals Edge Effect Analysis on orthogonal cutting the Plastic Metal Material-C10100 with Negative Rake Angle Tool

2020 ◽  
Vol 206 ◽  
pp. 02021
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi
Keyword(s):  
Edge Effect ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Contact Friction ◽  
Cutting Condition ◽  
Micro Cutting ◽  
Metal Material ◽  
Edge Radius ◽  
Plastic Metal ◽  
Tool Surface

With the rapid development of the precision grinding and micro-cutting technology, scholars have become more and more interested in the forming mechanism and related characteristics of the rounded-edge tool and the negative rake angle tool. Based on DEFORM-2D forming software, this paper investigates the edge effect of the negative rake angle tool in micro-cutting condition. Through the simulation comparison analysis, it is clear that three deformation regions appear in front of the tool surface, namely the first shear-slip region, the second tool-material contact friction region and the third edge effect deformation region when the negative rake tool cuts the plastic metal material-C10100 with a large edge radius. And a triangle stagnant region appears in front of the tool surface due to the edge effect. By analysing the influence of the ratio of the edge radius to the cutting thickness on the mechanism of orthogonal cutting of negative rake tools, it is found that the minimum cutting thickness value is between

An analytical force prediction model for turning operation by round insert considering edge effect

2017 ◽  
Vol 128-129 ◽  
pp. 168-180 ◽  
Author(s):  
Jian Weng ◽  
Kejia Zhuang ◽  
Ding Chen ◽  
Shunsheng Guo ◽  
Han Ding
Keyword(s):  
Prediction Model ◽  
Edge Effect ◽  
Turning Operation ◽  
Force Prediction

Methodology to establish a hybrid model for prediction of cutting forces and chip thickness in orthogonal cutting condition close to broaching

2018 ◽  
Vol 101 (5-8) ◽  
pp. 1357-1374 ◽  
Author(s):  
Gorka Ortiz-de-Zarate ◽  
Andres Sela ◽  
Mikel Saez-de-Buruaga ◽  
Mikel Cuesta ◽  
Aitor Madariaga ◽  
...  
Keyword(s):  
Hybrid Model ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Cutting Condition

Analytical and Thermal Modeling of High-Speed Machining With Chamfered Tools

2007 ◽  
Vol 130 (1) ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Heat Generation ◽  
High Speed ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
High Speed Machining ◽  
Temperature Distributions ◽  
Dead Metal Zone ◽  
Chamfered Tools

High-speed machining offers several advantages such as increased flexibility and productivity for discrete-part manufacturing. However, excessive heat generation and resulting high temperatures on the tool and workpiece surfaces in high-speed machining leads to a shorter tool life and poor part quality, especially if the tool edge geometry and cutting conditions were not selected properly. In this study, analytical and thermal modeling of high-speed machining with chamfered tools in the presence of dead metal zone has been presented to investigate the effects of cutting conditions, heat generation, and resultant temperature distributions at the tool and in the workpiece. An analytical slip-line field model is utilized to investigate the process mechanics and friction at the tool-chip and tool-workpiece interfaces in the presence of the dead metal zone in machining with a negative rake chamfered polycrystalline cubic boron nitride tool. In order to identify friction conditions, a set of orthogonal cutting tests is performed on AISI 4340 steel and chip geometries and cutting forces are measured. Thermal modeling of machining with chamfered tools based on moving band heat source theory, which utilizes the identified friction conditions and stress distributions on the tool-chip and tool-workpiece interfaces, is also formulated and temperature distributions at the tool, cutting zone, and in the workpiece are obtained. These temperature distributions are compared with the results obtained from finite element simulations. The comparison of temperature fields indicates that the proposed model provides reasonable solutions to understand the mechanics of machining with chamfered tools. Models presented here can be further utilized to optimize the tool geometry and cutting conditions for increasing benefits that high-speed machining offers.

Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes

2011 ◽  
Vol 223 ◽  
pp. 85-92 ◽  
Author(s):  
Balázs Tukora ◽  
Tibor Szalay
Keyword(s):  
Cutting Force ◽  
Real Time ◽  
Cutting Forces ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Work Piece ◽  
Processing Unit ◽  
Cutting Force Prediction ◽  
Force Prediction

In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

Cutting Force Prediction in Micro Orthogonal Cutting by an Analytical-Numerical Coupled Model

2015 ◽  
Author(s):  
A. Afsharhanaei ◽  
L. Rebaioli ◽  
P. Parenti ◽  
M. Annoni
Keyword(s):  
Cutting Force ◽  
Orthogonal Cutting ◽  
Coupled Model ◽  
Cutting Force Prediction ◽  
Force Prediction

scholarly journals Cutting Force Transition Model Considering the Influence of Tool System by Using Standard Test Table

Sensors ◽  
2021 ◽  
Vol 21 (4) ◽  
pp. 1340
Author(s):  
Xi Chen ◽  
Dinghua Zhang ◽  
Qi Wang
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Force Prediction ◽  
Actual Measurement ◽  
Tool Vibration ◽  
Force Prediction ◽  
Conversion Model ◽  
Proposed Model ◽  
The Impact

The cutting force prediction model usually uses the classical oblique transformation method, which introduces the orthogonal cutting parameters into the oblique milling edge shape, and combines the geometric parameters of the tool to convert the orthogonal cutting force into the actual cutting force, thereby predicting the cutting force. However, this cutting force prediction method ignores the impact of tool vibration in actual machining, resulting in a large difference between the prediction model and the actual measurement. This paper proposes a cutting force conversion model considering the influence of the tool system. The proposed model fully considers the impact of tool vibration on the cutting force. On the basis of the orthogonal model, superimposing the additional cutting force generated by tool vibration makes the predicted value of the model closer to the actual cutting force. The results of milling experiments show that the conversion model can obtain higher prediction accuracy. Moreover, compared with the original conversion model, the accuracy of the proposed model is significantly improved.

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