Experiment and Modeling of Milling Force Based on Tool Edge Preparation

2021 ◽  
Author(s):  
XF. Zhao ◽  
Y. Yang ◽  
L. He ◽  
ZG. Feng
Keyword(s):  
Milling Force ◽  
Tool Edge ◽  
Edge Preparation

scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

scholarly journals Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3974 ◽  
Author(s):  
Mohamed Shnfir ◽  
Oluwole A. Olufayo ◽  
Walid Jomaa ◽  
Victor Songmene
Keyword(s):  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Mechanical Shock ◽  
Tool Edge ◽  
Aisi 1045 ◽  
High Feed ◽  
1045 Steel ◽  
Edge Preparation

Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

Statistical Research on the Effects of Cutting Edge Preparation on Face Milling of Austenitic Stainless Steel Using FEM

2009 ◽  
Vol 407-408 ◽  
pp. 516-520
Author(s):  
Wei Wei Ming ◽  
Ming Chen
Keyword(s):  
Cutting Force ◽  
Stainless Steels ◽  
Austenitic Stainless Steels ◽  
Face Milling ◽  
Cutting Edge ◽  
Statistical Research ◽  
Element Analysis ◽  
Tool Edge ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Austenitic stainless steels are extensively used in the areas with high corrosion. The high heat resistance and strength make them difficult-to-cut materials. The tool life in machining austenitic stainless steels is restricted by the high cutting force and temperature which induce the tool wear and edge chipped. To achieve tool edge strength and reduce the edge-related problems, tool edge preparation is applied by introducing the chamfered and honed edges. In the current paper, the effects of the cutting edge preparation in face milling of austenitic stainless steels were studied using statistical method. The output cutting parameters as cutting force, temperature were obtained by finite element analysis. The purpose for this research is to give guidance to the tool edge preparation for machining stainless steels.

Edge Design for Regrinding Cutting Tool

2011 ◽  
Vol 101-102 ◽  
pp. 938-941
Author(s):  
Xin Li Tian ◽  
Hao Wang ◽  
Xiu Jian Tang ◽  
Zhao Li ◽  
Ai Bing Yu
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Edge Angle ◽  
Edge Radius ◽  
Tool Edge ◽  
Edge Defects ◽  
Tool Cutting ◽  
Edge Preparation

Regrinding of wasted cutting tools can recycle resources and decrease manufacturing costs. Influence of relative tool sharpness and tool cutting edge angle on tool edge radius were analyzed. Cutting force and cutting temperature were simulated with FEM on different edge radius. Edge preparation experiments were carried out though an abrasive nylon brushing method. The results show that RTS and cutting edge angle have influence on edge radius. Small edge radius might result in small cutting forces and lower average temperatures, could maintain the cutting state between tool and workpiece. The cutting edge defects can be eliminated through edge preparation, and a smooth cutting edge can be obtained. Cutting tool life will be improved through proper edge design and edge preparation.

Influence of Edge Preparation Parameters on the Cutting Edge in Drag Finishing

2016 ◽  
Vol 693 ◽  
pp. 1067-1073 ◽  
Author(s):  
Xue Feng Zhao ◽  
Lin He ◽  
Sen Yuan ◽  
Wei Juan Zheng
Keyword(s):  
Cutting Edge ◽  
Workpiece Surface ◽  
Orthogonal Experiments ◽  
Spindle Rotation ◽  
Tool Edge ◽  
Milling Tool ◽  
The Stability ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can eliminate defects and realize hone cutting edge, which can improve the quality of the workpiece surface, elevate the stability of cutting process and the tool life. In order to better investigate the edge preparation mechanism, the influence law of the edge preparation process parameters on the cutting edge is analyzed. The paper presents the single factor experiments and orthogonal experiments with the cemented carbide milling tool spindle rotation rate, edge preparation time, abrasive size and abrasive ratio in drag finishing. The edge preparation mechanism is revealed in the paper, which provides basis for the structure optimization of cutting edge contour.

Study of Micro-Tool Wear Based on Finite Element Method

2011 ◽  
Vol 314-316 ◽  
pp. 1806-1810
Author(s):  
Jin Feng Zhang ◽  
Ya Dong Gong ◽  
Yue Ming Liu ◽  
Jun Cheng ◽  
Xue Long Wen
Keyword(s):  
Tool Wear ◽  
Micro Milling ◽  
Operation Condition ◽  
Wear Model ◽  
Milling Force ◽  
Edge Radius ◽  
Tool Edge ◽  
Milling Tool ◽  
Milling Operation ◽  
Micro Tool

This paper presents mechanisms studies of micro scale milling operation focusing on micro cutter edge radius. To address this issue, the tool wear model is developed in the present work. Starting with an analysis of the milling edge radius of the tool, the influence of the downscaling on the edge radius is determined by analyzing the milling force. This simulation is used to predict the extent of tool wear in the same milling operation condition by increasing of the tool edge radius. This model accurately predicted the increasing of force with tool wear progress and provides the means for further study of the micro milling tool wear.

The Effect of Tool Edge Preparation of Indexable Carbide Insert

2012 ◽  
Vol 499 ◽  
pp. 342-347
Author(s):  
Xi Yue Zou ◽  
J.F. Sun ◽  
W.Y. Chen ◽  
J.X. Xie
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Cutting Temperature ◽  
Feed Force ◽  
Cutting Force Measurement ◽  
Tool Edge ◽  
Strain Gauge Dynamometer ◽  
Temperature Force ◽  
Edge Preparation ◽  
Carbide Insert

The paper focused on the effect of tool edge preparation of indexable carbide insert on cutting temperature, force and tool wear. The initial wear experiments were carried out to measure flank wear and two criteria to evaluate the effect of tool edge preparation were proposed. The cutting temperature measurement utilized tool-work thermocouple and revealed that the cutting temperature of honed insert was lower. The cutting force measurement with a strain gauge dynamometer showed that tangential cutting force Fz, feed force Fx would be increased and radius force Fy would be decreased after tool edge preparation.

Influence of Cutting Tool Edge Preparation on Cutting Force and Surface Integrity

2016 ◽  
Vol 836-837 ◽  
pp. 250-255
Author(s):  
Xue Feng Zhao ◽  
Lin He ◽  
Wei Liu ◽  
Wei Juan Zheng
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Practical Significance ◽  
Tool Edge ◽  
Radial Depth ◽  
Cutting Force Components ◽  
The Impact ◽  
Edge Preparation

The tool edge preparation has a significant influence on the quality of the workpiece surface, the stability of the cutting process and the tool life. In order to investigate the effect of the tool edge preparation, the impact on the cutting force components, the roughness and the residual stress is analyzed through the response surface methodology. The paper presents experimental results of turning tests with different edge radius and changing the cutting speed, the feed amount per tooth, the axial depth, and the radial depth. The research results will put forward theoretical value and practical significance to develop the processing technology of high-speed and efficient cutting, improve the metal cutting theory and prompt the development of the manufacture industry.

Study on the Influence of Different Tool Edge Radius on Milling Ti6Al4V

2010 ◽  
Author(s):  
Yueping Liu ◽  
Jianfeng Li ◽  
Jie Sun ◽  
Feng Jiang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Tool Life ◽  
Chip Morphology ◽  
Element Model ◽  
Fem Model ◽  
Edge Radius ◽  
Cutting Heat ◽  
Tool Edge ◽  
Edge Preparation

Short tool life is one of the bottleneck problems in Ti6Al4V machining. Edge preparation plays an important role on tool life. To investigate the influence of edge preparation on cutting force, cutting heat and chip morphology et al, Finite element model (FEM) is established. The software adopted in this study is ThirdWaveSystems AdvantEdge. Experiment is designed to verify the validation of the FEM model. Based on the validated FEM, optimized edge radius is obtained.

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