Residual stresses with different tool flank wear lengths in the ultra-precision machining of NiP alloys

1997 ◽  
Vol 65 (1-3) ◽  
pp. 116-126 ◽  
Author(s):  
Zone-Ching Lin ◽  
Wun-Ling Lai ◽  
H.Y. Lin ◽  
C.R. Liu
Keyword(s):  
Residual Stresses ◽  
Flank Wear ◽  
Precision Machining ◽  
Tool Flank Wear ◽  
Ultra Precision

The influence of tool flank wear on residual stresses induced by milling aluminum alloy

2009 ◽  
Vol 209 (9) ◽  
pp. 4502-4508 ◽  
Author(s):  
Z.T. Tang ◽  
Z.Q. Liu ◽  
Y.Z. Pan ◽  
Y. Wan ◽  
X. Ai
Keyword(s):  
Aluminum Alloy ◽  
Residual Stresses ◽  
Flank Wear ◽  
Tool Flank Wear

Role of Tool Flank Wear and Machining Speed in Developing of Residual Stress in Machined Surface During High Speed Machining of Titanium Alloys

2015 ◽  
Author(s):  
Xueping Zhang ◽  
Rajiv Shivpuri ◽  
Anil K. Srivastava
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
High Speed ◽  
Flank Wear ◽  
Tool Geometry ◽  
High Speed Machining ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machining Speed

Residual stresses generated from finish machining have a significant impact on the fatigue life of mechanical components by controlling crack initiation and propagation processes in their near subsurface. As governing variables, tool geometry, tool wear, machining parameter, work material property, and lubrication conditions have been widely studied to determine their effects on residual stress pattern in machined surface and subsurface. Among those parameters, tool flank wear was seldom fully investigated although tool flank wear, as well as machining speed, has been identified as the most important contributor to residual stress. Especially, tool flank wear becomes more significant due to the poor work thermal property during the high speed machining of titanium Ti-6Al-4V alloy. This study aims to investigate the combined role of tool flank wear and machining speed in developing residual stress in the machining of titanium alloy using finite element method. A microstructure sensitive material model based on Self Consistent Method (SCM) is adopted to incorporate the phase state and its transformations during machining cycle. Critical flank wear land and corresponding machining speeds are identified, beyond which compressive residual stresses are transferred into tensile residual stresses. High machining speeds demonstrate a distinct influence on residual stresses by means of promoting tool flank wear rate. The numerical simulation results are validated by empirical data provided in previous research.

Influence of Dry Cut and Tool Wear on Residual Stresses in High Speed Machining of Nickel-Based Superalloy

2013 ◽  
Vol 768-769 ◽  
pp. 470-477 ◽  
Author(s):  
Ru Lin Peng ◽  
Jin Ming Zhou ◽  
Sten Johansson ◽  
Annethe Bellinius ◽  
Volodymr Bushlya ◽  
...  
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Minor Effect ◽  
Contrast Imaging ◽  
Tool Flank Wear ◽  
Tensile Stresses

Machining induced residual stresses were investigated in Inconel 718 prepared by high speed turning under dry cut condition. The influence of cutting tool wear and the use of cutting fluid were studied. By x-ray diffraction measurements, characteristic residual stress distributions with tensile stresses in the top layer and compressive stresses in the layer below were found in all the investigated samples. The magnitude of surface tensile stresses and size of the tension as well as compression zones varied depending on the cutting condition. The application of cutting fluid for turning using new tool has a minor effect, giving a somewhat larger subsurface compressive zone but reducing the surface tensile stresses. Tool flank wear has shown a much stronger effect. While a flank wear of VBmax=0.15 mm enhanced mostly the surface tensile residual stresses, a severer wear of VBmax=0.3 mm greatly increased the thickness of the subsurface compression zone and at the same time resulted in strong stress anisotropy. Microstructural study by electron channelling contrast imaging shows that the observed influence of tool flank wear or cutting fluid on residual stresses are related to different contributions from increased plastic deformation and cutting heat, which changed with the cutting conditions.

scholarly journals 3D Hybrid Numerical Model of Residual Stresses: Numerical—Sensitivity to Cutting Parameters When Turning 15-5PH Stainless Steel

2021 ◽  
Vol 5 (3) ◽  
pp. 70
Author(s):  
Alexandre Mondelin ◽  
Frédéric Valiorgue ◽  
Joël Rech ◽  
Michel Coret
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Hybrid Model ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Residual Stress State

This paper investigates the residual stresses induced by a longitudinal turning operation in 15-5PH martensitic stainless steel. An experimental investigation has quantified the sensitivity of residual stresses to cutting speed, feed, tool geometry and tool flank wear. In parallel, a 3D hybrid model, previously developed, has been applied to each case study. This modelling approach consists of replacing tooling and chipping by equivalent thermal and mechanical loadings. These equivalent loadings are moved onto the machined surface to compute the final residual stress state. It has shown that tool geometry and tool flank wear have a dominant effect on residual stresses compared to cutting speed and feed rate. However, cutting speed influences the intensity of the compressive peak, to some extent, whereas feed influences the affected depth. This work has also shown that the 3D hybrid model is able to predict residual stresses, as well as the sensitivity to cutting parameters, with reasonable agreement.

scholarly journals A Self-Established “Machining-Measurement-Evaluation” Integrated Platform for Taper Cutting Experiments and Applications

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 929
Author(s):  
Xudong Yang ◽  
Zexiao Li ◽  
Linlin Zhu ◽  
Yuchu Dong ◽  
Lei Liu ◽  
...  
Keyword(s):  
Three Dimensional ◽  
Precision Machining ◽  
Two Dimensional ◽  
Dimensional Image ◽  
Two Dimensional Image ◽  
Integrated Platform ◽  
Hard And Brittle Materials ◽  
Ultra Precision ◽  
Cutting Experiments

Taper-cutting experiments are important means of exploring the nano-cutting mechanisms of hard and brittle materials. Under current cutting conditions, the brittle-ductile transition depth (BDTD) of a material can be obtained through a taper-cutting experiment. However, taper-cutting experiments mostly rely on ultra-precision machining tools, which have a low efficiency and high cost, and it is thus difficult to realize in situ measurements. For taper-cut surfaces, three-dimensional microscopy and two-dimensional image calculation methods are generally used to obtain the BDTDs of materials, which have a great degree of subjectivity, leading to low accuracy. In this paper, an integrated system-processing platform is designed and established in order to realize the processing, measurement, and evaluation of taper-cutting experiments on hard and brittle materials. A spectral confocal sensor is introduced to assist in the assembly and adjustment of the workpiece. This system can directly perform taper-cutting experiments rather than using ultra-precision machining tools, and a small white light interference sensor is integrated for in situ measurement of the three-dimensional topography of the cutting surface. A method for the calculation of BDTD is proposed in order to accurately obtain the BDTDs of materials based on three-dimensional data that are supplemented by two-dimensional images. The results show that the cutting effects of the integrated platform on taper cutting have a strong agreement with the effects of ultra-precision machining tools, thus proving the stability and reliability of the integrated platform. The two-dimensional image measurement results show that the proposed measurement method is accurate and feasible. Finally, microstructure arrays were fabricated on the integrated platform as a typical case of a high-precision application.

scholarly journals An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 755
Author(s):  
Chen-Yang Zhao ◽  
Chi-Fai Cheung ◽  
Wen-Peng Fu
Keyword(s):  
Precision Measurement ◽  
Detection Algorithm ◽  
Surface Generation ◽  
Precision Machining ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Transition Points ◽  
Cutting Strategy

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

Study on Ultra-Precision Ball Surface Floating Polishing Kinematics Mechanism

2006 ◽  
Vol 532-533 ◽  
pp. 109-112
Author(s):  
Xun Lv ◽  
Ju Long Yuan ◽  
Dong Hui Wen ◽  
Qian Fa Deng ◽  
Fei Yan Lou
Keyword(s):  
Chemical Conversion ◽  
Processing Parameters ◽  
Precision Machining ◽  
High Tech ◽  
National Defense ◽  
Ball Surface ◽  
Angular Velocities ◽  
Ultra Precision ◽  
Relationship Of ◽  
The Mathematical Model

The high precision balls are requested in national defense, astronautics and high-tech commercial domain urgently. Conventional precision machining methods are sensitive to uniformity of abrasives and machining environment. After precision machining, there are easily to produce thick damaged layer on the ball surface because of machining stress and chemical conversion. On the basis of the floating polishing mechanism, a new scatheless ultra-precision polishing method of ball surface can solve the problems of abrasives uniformity effectively and damaged layer. In order to ensure that the new polishing method polishes ball surface equally, the appropriate angular velocities of the ball should be selected. This paper sets up the mathematical model about the motion of ball. By analyzing and simulating the relationship of the angular velocities, the best processing parameters are acquired.

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