An analytical model for micro-cutting considering the cutting tool edge radius effect and material separation

2021 ◽  
Vol 114 (1-2) ◽  
pp. 97-105
Author(s):  
Yiquan Li ◽  
Zhanjiang Yu ◽  
Jinkai Xu ◽  
Xiaozhou Li ◽  
Huadong Yu
Keyword(s):  
Analytical Model ◽  
Cutting Tool ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Material Separation

On the Steady-State Workpiece Flow Mechanism and Force Prediction Considering Piled-Up Effect and Dead Metal Zone Formation

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Cheng Hu ◽  
Weiwei Zhang ◽  
Kejia Zhuang ◽  
Jinming Zhou ◽  
Han Ding
Keyword(s):  
Stagnation Point ◽  
Shear Stresses ◽  
Flow Mechanism ◽  
Zone Formation ◽  
Force Prediction ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Dead Metal Zone ◽  
Tool Edge ◽  
Material Separation

Abstract The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three points characterizing the DMZ pattern and one inside considered as stagnation point. The normal and shear stresses as well as friction factors along the entire contact region are clarified based on slip-line theory. It is found that the friction coefficient varies symmetrically about the stagnation point inside DMZ and remains constant for the rest. Then, an analytical force prediction model is developed with Johnson–Cook constitutive model, involving calibrated functions of chip-tool contact length and cutting temperature. The assumed tribology condition and morphologies of material separation including DMZ are clearly observed and verified through various finite element (FE) simulations. Finally, comparisons of cutting forces from cutting experiments and predicted results are adopted for the validation of the predictive model.

An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

2005 ◽  
Vol 128 (2) ◽  
pp. 474-481 ◽  
Author(s):  
X. Liu ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Analytical Model ◽  
Chip Thickness ◽  
Machining Process ◽  
Thickness Effect ◽  
Uncut Chip Thickness ◽  
Minimum Chip Thickness ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Velocity

In micromachining, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. The minimum chip thickness effect significantly affects machining process performance in terms of cutting forces, tool wear, surface integrity, process stability, etc. In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization. The model accounts for the effects of thermal softening and strain hardening on the minimum chip thickness. The influence of cutting velocity and tool edge radius on the minimum chip thickness has been taken into account. The model has been experimentally validated with 1040 steel and Al6082-T6 over a range of cutting velocities and tool edge radii. The developed model has then been applied to investigate the effects of cutting velocity and edge radius on the normalized minimum chip thickness for various carbon steels with different carbon contents and Al6082-T6.

Finite Element Analysis of Cutting Force and Burr Formation in Micro-Cutting of Titanium Alloy Considering Tool Edge Radius

2012 ◽  
Vol 426 ◽  
pp. 235-238 ◽  
Author(s):  
Da Peng Dong ◽  
Xiao Hu Zheng ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Cutting Force ◽  
Simulation Modeling ◽  
Burr Formation ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Cutting Energy ◽  
Burr Size ◽  
Edge Radius ◽  
Tool Edge

In recent years, with the development of machinery industry, micro-cutting technologies have been gradually moving into engineering realization. The paper carries out a series of works on simulation modeling of micro-cutting of Ti-5Al-5V-5Mo-3Cr considering tool edge radius. Unlike conventional cutting, in micro-cutting the effect of tool edge radius which has a marked impact on cutting force, specific cutting energy, burr formation and burr size can no longer be neglected.

A Study of Exit-Burr Formation Mechanism Using the Finite Element Method in Micro-Cutting of Aluminum Alloy

2008 ◽  
Vol 375-376 ◽  
pp. 470-473 ◽  
Author(s):  
Dong Lu ◽  
Jian Feng Li ◽  
Yi Ming Rong ◽  
Jie Sun ◽  
Jun Zhou ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Chip Thickness ◽  
Burr Formation ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Speed Effect ◽  
Exit Burr

A burr formation process in micro-cutting of Al7075-T7451 was analyzed. Three stages of burr formation including steady-state cutting stage, pivoting stage, and burr formation stage are investigated. And the effects of uncut chip thickness, cutting speed and tool edge radius on the burr formation are studied. The simulation results show that the generation of negative shear zone is one of the prime reasons for burr formation. Uncut chip thickness has a significant effect on burr height; however, the cutting speed effect is minor. Unlike in conventional cutting, in micro-cutting the effect of tool edge radius on the burr geometry can no longer be neglected.

Finite Element Analysis of Micro-Cutting Aluminum 7050-T7451 with the Tool Edge Radius Considered

2010 ◽  
Vol 443 ◽  
pp. 663-668 ◽  
Author(s):  
Jun Zhou ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Cutting Temperature ◽  
Machining Process ◽  
Micro Machining ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

2011 ◽  
Vol 223 ◽  
pp. 859-868 ◽  
Author(s):  
Shukri Afazov ◽  
Svetan Ratchev ◽  
Joel Segal
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Micro Milling ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Stability Lobes ◽  
Tool Edge ◽  
The Stability

This paper investigates the effects of the cutting tool edge radius on the cutting forces and stability lobes in micro-milling. The investigation is conducted based on recently developed models for prediction of micro-milling cutting forces and stability lobes. The developed models consider the nonlinearities of the micro-milling process, such as nonlinear cutting forces due to cutting velocity dependencies, edge radius effect and run-out presence. A number of finite element analyses (FEA) are performed to obtain the cutting forces in orthogonal cutting which are used for determining the micro-milling cutting forces. The chip morphology obtained for different tool edge radii using FEA is presented. It is observed that at large tool edge radii the influence of the ploughing effect become more significant factor on the chip morphology. The results related to micro-milling cutting forces and stability lobes show that by enlarging the tool edge radius the micro-milling cutting forces increase while the stability limits decrease.

Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

2016 ◽  
Vol 836-837 ◽  
pp. 374-380
Author(s):  
Teng Yi Shang ◽  
Li Jing Xie ◽  
Xiao Lei Chen ◽  
Yu Qin ◽  
Tie Fu
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Multiphase Model ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Insert ◽  
Multiphase Models ◽  
Hot Rolled ◽  
Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

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