Advanced cooling-lubrication technologies in metal machining

2022 ◽  
pp. 67-92
Author(s):  
Mozammel Mia ◽  
Muhommad Azizur Rahman ◽  
Munish Kumar Gupta ◽  
Neeraj Sharma ◽  
Mohd Danish ◽  
...  
Keyword(s):  
Metal Machining

Dynamics of the processes in metal machining

1998 ◽  
Vol 2 ◽  
pp. 115-122
Author(s):  
Donatas Švitra ◽  
Jolanta Janutėnienė
Keyword(s):  
High Frequency ◽  
Machine Tools ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Low Frequency ◽  
Metal Cutting Machine ◽  
Cutting Machine ◽  
Metal Machining

In the practice of processing of metals by cutting it is necessary to overcome the vibration of the cutting tool, the processed detail and units of the machine tool. These vibrations in many cases are an obstacle to increase the productivity and quality of treatment of details on metal-cutting machine tools. Vibration at cutting of metals is a very diverse phenomenon due to both it’s nature and the form of oscillatory motion. The most general classification of vibrations at cutting is a division them into forced vibration and autovibrations. The most difficult to remove and poorly investigated are the autovibrations, i.e. vibrations arising at the absence of external periodic forces. The autovibrations, stipulated by the process of cutting on metalcutting machine are of two types: the low-frequency autovibrations and high-frequency autovibrations. When the low-frequency autovibration there appear, the cutting process ought to be terminated and the cause of the vibrations eliminated. Otherwise, there is a danger of a break of both machine and tool. In the case of high-frequency vibration the machine operates apparently quiently, but the processed surface feature small-sized roughness. The frequency of autovibrations can reach 5000 Hz and more.

3D Finite Element Simulation for Turning of Hardened 45 Steel

2019 ◽  
Vol 13 (2) ◽  
pp. 181-188
Author(s):  
Meng Liu ◽  
Guohe Li ◽  
Xueli Zhao ◽  
Xiaole Qi ◽  
Shanshan Zhao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Orthogonal Experiment ◽  
Element Model ◽  
3D Finite Element ◽  
Element Simulation ◽  
Metal Machining ◽  
Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

scholarly journals Metal Machining—Recent Advances, Applications, and Challenges

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 580
Author(s):  
Francisco J. G. Silva
Keyword(s):  
Surface Finish ◽  
Manufacturing Process ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
High Dimensional ◽  
Manufacturing Processes ◽  
Recent Advances ◽  
Metal Machining ◽  
Rapid Manufacture

Though new manufacturing processes that revolutionize the landscape regarding the rapid manufacture of parts have recently emerged, the machining process remains alive and up-to-date in this context, always presenting itself as a manufacturing process with several variants and allowing for high dimensional accuracy and high levels of surface finish [...]

Development of Three-Dimensional Parametric Modeling for Milling Process Simulation

2010 ◽  
Vol 139-141 ◽  
pp. 1178-1183
Author(s):  
Jing Sheng ◽  
Guang Guo Zhang ◽  
Hong Hua Zhang
Keyword(s):  
3D Modeling ◽  
Process Simulation ◽  
Three Dimensional ◽  
Milling Process ◽  
Parametric Modeling ◽  
Machining Simulation ◽  
Metal Machining ◽  
Simulation Results ◽  
Key Techniques ◽  
Access Data

Metal machining simulation using finite element method (FEM) is extraordinarily complex. It is essential to develop a system so as to construct simulation model and obtain valuable results conveniently and rapidly. This study developed a parametric modeling based on MSC.Marc software, which included the key techniques of three-dimensional (3D) modeling and the parametric modeling course of metal milling process. In addition, an explanation facility based on the procedure file, which could be run automatically, was performed according to a modeling procedure. The interface of the system designed using Builder, could access data, which included the geometric angles and the dimensions of a tool and a workpiece, the relative position between them, their properties and cutting conditions, etc.. Calling the procedure file, the system approached the parametric modeling. An example was given, which simulation results indicated that it is an effective methodology to develop 3D parametric modeling.

Review Microstructure of Nickel-Based Single-Crystal CMSX-4 Superalloy after Electrochemical Machining

2021 ◽  
Author(s):  
Ali Mehrvar ◽  
Alireza Mirak ◽  
Mohsen Motamedi
Keyword(s):  
Single Crystal ◽  
Electrochemical Machining ◽  
Free Surfaces ◽  
Gamma Prime ◽  
Eds Analysis ◽  
Metal Machining ◽  
Before And After ◽  
Gamma Field ◽  
High Level ◽  
Two Sides

Abstract A special position has been created for using the nickel-based single-crystal CMSX-4 superalloy at high temperatures due to the improved mechanical properties of this material and the absence of grain boundary in the crystal lattice. Also, electrochemical machining can be an effective method for machining this superalloy due to its unique performance in metal machining, like creating stress-free surfaces, high-level surface smoothness, and machining of complex geometries. This single crystal superalloy's microstructure consists of three phases: Gamma, Gamma prime, and a bit of carbide. Gamma prime is distributed cubically and homogeneously in the Gamma field without any boundaries and as a single crystal. It is essential not to change the microstructure after the production process or machining. In the present research, electrochemical machining was performed on CMSX-4 single crystal superalloy. The workpiece's microstructure was then investigated before and after electrochemical machining using scanning electron microscopy and EDS analysis from two sides. No changes were seen in CMSX-4 infrastructure after electrochemical machining EDS analysis and Images.

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