A novel method to continuously map the surface integrity and cutting mechanism transition in various cutting conditions

2020 ◽  
Vol 151 ◽  
pp. 103529 ◽  
Author(s):  
Dongdong Xu ◽  
Zhirong Liao ◽  
Dragos Axinte ◽  
Mark Hardy
Keyword(s):  
Surface Integrity ◽  
Cutting Conditions ◽  
Cutting Mechanism ◽  
Novel Method ◽  
Mechanism Transition

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

scholarly journals Kinematic Design of a Seven-Bar Linkage with Optimized Centrodes for Pure-Rolling Cutting

2017 ◽  
Vol 2017 ◽  
pp. 1-11 ◽  
Author(s):  
Biao Liu ◽  
Yali Ma ◽  
Delun Wang ◽  
Shaoping Bai ◽  
Yangyang Li ◽  
...  
Keyword(s):  
Optimal Solution ◽  
Genetic Optimization ◽  
Dimensional Synthesis ◽  
Cutting Mechanism ◽  
Pure Rolling ◽  
Moving Points ◽  
Novel Method ◽  
Design Requirements ◽  
Genetic Optimization Algorithm ◽  
Peak Value

A novel method for designing a seven-bar linkage based on the optimization of centrodes is presented in this paper. The proposed method is applied to the design of a pure-rolling cutting mechanism, wherein close interrelation between the contacting lines and centrodes of two pure-rolling bodies is formulated and the genetic optimization algorithm is adopted for the dimensional synthesis of the mechanism. The optimization is conducted to minimize the error between mechanism centrodes and the expected trajectories, subject to the design requirements of the opening distance, the maximum amount of overlap error, and peak value of shearing force. An optimal solution is obtained and the analysis results show that the horizontal slipping and standard deviation of the lowest moving points of the upper shear blade have been reduced by 78.0% and 80.1% and the peak value of shear stress decreases by 29%, which indicate better cutting performance and long service life.

scholarly journals Studying of cutting conditions when hard turning and their impact on integrity of shaped-complex surfaces

2018 ◽  
Vol 157 ◽  
pp. 05010
Author(s):  
Jozef Holubjak ◽  
Jozef Pilc ◽  
Tatiana Czanova ◽  
Pavol Martikan ◽  
Dusan Mital ◽  
...  
Keyword(s):  
Residual Stress ◽  
Surface Integrity ◽  
Hard Turning ◽  
Subsurface Layer ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Complex Surfaces

This article deals with impact of cutting conditions when hard turning of shaped-complex surfaces which are concentration origin of cracks especially in the area of notches. These areas significantly reduce the lifetime and functionality of surface by degradation of surface integrity where are the significant number of destruction cracks. Actual experiments are focused on detection of impact of each individual cutting condition on the generation of residual stress and its impact in each surface and subsurface layer of material. Results and evaluations explain what way is necessary to design and apply cutting conditions when hard turning of shaped-complex surfaces.

The Effects of Cutting Conditions on Surface Integrity in Machining Inconel 718 Alloy

2013 ◽  
Vol 554-557 ◽  
pp. 2093-2100 ◽  
Author(s):  
Domenico Umbrello
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Cutting Conditions ◽  
Machining Process ◽  
Process Performance ◽  
Inconel 718 Alloy ◽  
Dry Conditions ◽  
Rapid Tool ◽  
Cutting Speeds

Machining of advancedaerospace materials have grown in the recent years although the hard-to-machinecharacteristics of alloys like titanium or nickel based alloys cause highercutting forces, rapid tool wear, and more heat generation. This paper presentsan experimental evaluation of machining ofInconel718alloy under dry conditions at varying of cutting speeds and feed rates.The influence of the cutting conditions on surface integrity was studied interms of surface roughness, affected layer, grain size variations and phasechanges/modification. Also, the machining process performance was evaluatedthrough the power consumption and tool-wear.

Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis

1999 ◽  
Vol 122 (4) ◽  
pp. 620-631 ◽  
Author(s):  
T. I. El-Wardany ◽  
H. A. Kishawy ◽  
M. A. Elbestawi
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Tool Steel ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Conditions ◽  
Metallographic Analysis ◽  
Tool Geometry ◽  
Machined Surface ◽  
Geometrical Defects

The effects of cutting conditions and tool wear on chip morphology and surface integrity during high speed machining of D2 tool steel (60–62 Hrc) are investigated experimentally and analytically in this paper. Polycrystalline Cubic Boron Nitride (PCBN) tools are used in this investigation. The chips and the subsurface of the workpiece are examined using optical and scanning electron microscopy. Microhardness measurements are performed on the surface and subsurface of the workpiece. The X-ray diffraction technique is used to measure the residual stresses induced in the machined surface. The paper is divided into two parts. Part 1 presents the results obtained from the micrographical analysis of the chips and the surfaces produced. Part 2 deals with microhardness and residual stresses of the machined surface. The micrographical analysis of the chips produced shows that different mechanisms of chip formation exist depending on the magnitude of the cutting pressure and tool wear. Saw toothed chips are produced during the machining of D2 tool steel if the cutting pressure exceeds approximately 4000 MPa. The metallographic analysis of the surface produced illustrates the damaged surface region that contains geometrical defects and changes in the subsurface metallurgical structure. The types of surface damage are dependent on the cutting conditions, tool geometry and the magnitude of the wear lands. [S1087-1357(00)00104-0]

OP-PLAN: An Automated Operation Planning System for Turned Components

1989 ◽  
Vol 203 (3) ◽  
pp. 145-158 ◽  
Author(s):  
S Hinduja ◽  
H Huang
Keyword(s):  
Large Percentage ◽  
Cutting Conditions ◽  
Planning System ◽  
Operation Planning ◽  
Optimum Cutting ◽  
Novel Method ◽  
Cost Calculations ◽  
Oriented System

OP-PLAN is one of the modules of TECHTURN (1) which is a technologically oriented system for turned components. Given the geometry of the component, OP-PLAN recognizes, in the first instance, features such as threads, grooves and recesses, and then subdivides the rest of the component into volumes. A novel method is presented which determines simultaneously the optimum subdivision of the stock into volumes and the most suitable operation. In arriving at the solution, cost calculations are performed based on optimum cutting conditions calculated with standard tools having indexable inserts. For other features, preassigned operations are used. The sequence of operations is based on commonly accepted rules used in turning and care is taken to ensure that the technological requirements can be guaranteed. OP-PLAN caters for all axisymmetrical features and therefore it should be able to deal with a fairly large percentage of turned components found in industry. Three examples are included and they highlight some of the features of the system.

Links Between Machining Parameters and Surface Integrity in Drilling Ni-Superalloy

2010 ◽  
Vol 112 ◽  
pp. 171-178 ◽  
Author(s):  
Vincent Dutilh ◽  
Gilles Dessein ◽  
Joël Alexis ◽  
Géraldine Perrin
Keyword(s):  
Surface Integrity ◽  
Tool Material ◽  
High Energy ◽  
Cutting Conditions ◽  
Nickel Base Superalloy ◽  
Machining Parameters ◽  
Hardness Tests ◽  
Metallurgical Analysis ◽  
Optical Profilometer ◽  
Nickel Base

In aerospace industry, the manufacturing of critical parts (high energy components) requires an important validation process to guarantee the quality of the produced parts, and thus their fatigue lifecycle. Globally, this validation consists in freezing the cutting conditions using metallurgical analysis or fatigue trials, and a test on the first article. This process is extremely complex and expensive. In this way establishing the correlation between the cutting conditions and the surface integrity will help us to optimize the manufacture of those parts. In this article, by the means of an experimental method, we define a domain of validation by combining the cutting conditions according to the classic criteria established by AFNOR E66-520 norm (Couple-Tool-Material) and the criteria of surface integrity for the drilling of a Nickel-base superalloy. The experimental device consists in drilling a Ø15.5 mm hole on a 3-axis milling centre instrumented by a 4 components Kistler dynamometer (Fx, Fy, Fz and Mz), a spindle power sensor “Watt-pilote” and three accelerometers placed following the directions X, Y and Z. Scanning Electron Microscopy (SEM) observations, micro-hardness tests and topographic measurements with an optical profilometer, are carried out to characterize the metallurgical state of the holes manufactured. Finally, correlations were respectively made between the cutting conditions, the recorded signals and the metallurgical state of the holes.

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