scholarly journals Mechanistic modeling of cutting forces in high-speed microturning of titanium alloy with consideration of nose radius

2021 ◽  
Author(s):  
Kubilay Aslantas ◽  
Şükrü Ülker ◽  
Ömer Şahan ◽  
Danil Yu Pimenov ◽  
Khaled Giasin
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Mechanistic Model ◽  
Cutting Speed ◽  
Mechanistic Modeling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Multilinear Regression Analysis ◽  
Edge Radius

AbstractMicroturning is a micromechanical machining process used to produce microcylindrical or axially symmetrical parts. Microcylindrical parts are mainly used in microfluidic systems, intravenous micromotors, microsurgical applications, optical lens applications, and microinjection systems. The workpiece diameter is very small in microturning and therefore is greatly affected by the cutting forces. For this reason, it is important to predict the cutting forces when machining miniature parts. In this study, an analytical mechanistic model of microturning is used to predict the cutting forces considering the tool nose radius. In the semi-empirically developed mechanistic model, the tool radius was considered. A series of semi-orthogonal microturning cutting tests were carried out to determine the cutting and edge force coefficients. The mechanistic model was generalized depending on the cutting speed and depth of cut by performing multilinear regression analysis. In the study, the depth of cut (ap = 30–90 µm) and feed values (f = 0.5–20 µm/rev) were selected considering the nose radius and edge radius of the cutting tool. The experiments were carried out under high-cutting speeds (Vc = 150–500 m/min) and microcutting conditions. Ti6Al4V alloy was used as the workpiece material and the tests were carried out under dry cutting conditions. Validation tests for different cutting parameters were carried out to validate the accuracy of the developed mechanistic model. The results showed that the difference between the mechanistic model and the experimental data was a minimum of 3% and a maximum of 24%. The maximum difference between the experimental and the model usually occurs in forces in the tangential direction. It has been observed that the developed model gives accurate results even at a depth of cut smaller than the nose radius and at feed values smaller than the edge radius.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Influence of the Cutting Parameters on the Cutting Forces of Carbon Steel

2002 ◽  
Author(s):  
Zulay Cassier ◽  
Patricia Mun˜oz-Escanola ◽  
Rolda´n Sa´nchez
Keyword(s):  
Carbon Steel ◽  
Cutting Forces ◽  
Low Cost ◽  
Cutting Parameters ◽  
Carbon Steels ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 1045 ◽  
Alloy Steels

Plain carbon steels and alloy steels have a great application in the manufacturing process especially due to their characteristic of high machinability and low cost. The machining of these materials, the study of the cutting forces, and the power required for the cutting process is one of the most important parameters to be evaluated. The relationship between this parameter and the other cutting variables process is crucial for the optimization of the machining process. The results of this research are empirical expressions, obtained from the cutting parameters (tool nose radius, feed rate and depth of cut) and the influence of these parameters on the cutting forces for each carbon steel studied (AISI 1020, AISI 1045 and AISI 4340), as well as a general expression which includes the mechanical properties of these carbon steels. These results enable the user to predict cutting forces when using a turning process.

Cutting Forces in High Speed Milling of Hardened Steel by Coated Tool

2009 ◽  
Vol 69-70 ◽  
pp. 418-422
Author(s):  
L.D. Wu ◽  
Cheng Yong Wang ◽  
D.H. Yu ◽  
Yue Xian Song
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Coated Tool ◽  
Radial Depth ◽  
Solid Carbide ◽  
End Mills

Hardened steel P20 at 50 HRC is milled at high speed by TiN coated and TiAlN coated solid carbide straight end mills, and the cutting forces and tool wear are measured. The result shows that TiAlN coated tool is more suitable for cutting hardened steel at high speed. Then the hardened steel is milled under different cutting parameters. It is indicated that the effect of cutting speed on cutting forces is small, but the effect of cutting speed on machine vibration should be considered. Increase feed per tooth or radial depth of cut will increase the cutting forces.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

Prediction of the Cutting Forces on Stainless Steels When Using a Turning Process

2003 ◽  
Author(s):  
Zulay Cassier ◽  
Patricia Mun˜oz-Escalona ◽  
Jannelly Moreno
Keyword(s):  
Stainless Steels ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Turning Process ◽  
High Corrosion Resistance ◽  
Aisi 304 ◽  
Heat Treated

Stainless steels have a great application in the manufacturing process especially due to their characteristic high corrosion resistance. The machining of these materials, the study of the cutting forces, and the power required for the cutting are important parameters to be evaluated. Their relationship with other cutting variables process is crucial for the optimization of the machining process. The results of this research are empirical expressions relating cutting parameters (cutting speed, feed rate and depth of cut) to cutting forces for each stainless steel studied, AISI 304, AISI 420 and AISI 420HT (HT: Heat treated). A general expression was also developed which includes the mechanical properties of these stainless steels. These results enable the user to predict cutting forces when using a turning process.

Machining Apprenticeship Based on Experimental Training Practice

2011 ◽  
Vol 692 ◽  
pp. 83-92
Author(s):  
Pedro Jose Arrazola ◽  
A. Villar ◽  
R. Fernández ◽  
J. Aperribay
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Feed Rate ◽  
Cutting Forces ◽  
Theoretical Calculations ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Practical Training ◽  
Input Parameters

This article describes a practical machining training aiming that the students acquire the theoretical-practical knowledge of chip formation process. The training takes place after theoretical lessons of machining processes. Thus, this practice allows strengthening the knowledge gained during the lessons. The practical training lasts for five hours, and the student assisted by the teacher analyses the influence of some machining entry parameters (cutting speed, feed rate...) on exit parameters like: (I) cutting forces and power consumption, (II) surface roughness, and (III) chip typology. The practical session is carried out on an experimental set-up (Lathe CNC Danobar 65) equipped with sensors and devices to measure forces (sensor Kistler 9121) and power consumption. In addition, a portable rugosimeter (Hommelwerke) is employed to perform surface roughness measurements. No especial devices are needed for the chip typology analysis. In the case of cutting forces and power consumption, the following input parameters influences are analysed: feed rate, depth of cut and cutting speed. In the case of surface roughness analysis, the following input parameters influences are analysed: feed rate and nose radius of the cutting insert. Finally, regarding chip typology feed rate and depth of cut are examined. The experimental results are compared with model predictions (theoretical calculations) for the three issues studied. The students have to compare both results: theoretical an empirical and they need to explain the reasons when discrepancies appear. Results obtained during the last years demonstrate the student acquires better knowledge of the machining process, and at the same time realises of the process complexity.

Linear Sawing Apparatus and its Evaluation for Research Into High Speed Bone Sawing

2011 ◽  
Author(s):  
John J. Pearlman ◽  
Anil Saigal ◽  
Thomas P. James
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Material Behavior ◽  
Depth Of Cut ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Saw Blade

Previous research into the cutting mechanics of bone sawing has been primarily approached from the perspective of orthogonal metal machining with a single edge cutting tool. This was a natural progression from the larger body of knowledge on the mechanics of metal cutting. However, there are significant differences between typical orthogonal metal cutting parameters and those encountered in bone sawing, such as anisotropic material behavior, depth of cut on the order of cutting edge radius, chip formation mechanism in the context of a saw blade kerf, non-orthogonal considerations of set saw blade teeth, and cutting speed to name a few. In the present study, an attempt is made to overcome these shortcomings by employing a unique sawing fixture, developed to establish cutting speeds equivalent to those of typical sagittal saws used in orthopaedic procedures. The apparatus was developed for research into bone sawing mechanics and is not intended to be a commercial sawing machine. The sawing fixture incorporates the cutting speed possible with lathe operations, as well as the linear cutting capabilities of a milling machine. Depths of cut are on the same order of magnitude as the cutting edge radius typical to saw blade teeth. Initial measurements of cutting and thrust force, obtained with this new experimental equipment, are compared to previous work.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

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