Numerical investigations on the effect of ultra-high cutting speed on the cutting heat and rock-breaking performance of a single cutter

2020 ◽  
Vol 190 ◽  
pp. 107120
Author(s):  
Mingyang Gao ◽  
Kai Zhang ◽  
Qin Zhou ◽  
Huifeng Zhou ◽  
Baolin Liu ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Rock Breaking ◽  
Numerical Investigations ◽  
High Cutting Speed ◽  
Cutting Heat

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

Mechanism of Variable Helix Tools in Suppressing Chatter Using Process Damping for Machining Titanium Alloys at Low Cutting Speed

2013 ◽  
Vol 773-774 ◽  
pp. 370-376
Author(s):  
Muhammad Adib Shaharun ◽  
Ahmad Razlan Yusoff ◽  
Mohammad S. Reza
Keyword(s):  
Titanium Alloy ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Process ◽  
Chatter Vibration ◽  
Process Damping ◽  
High Cutting Speed ◽  
Titanium Machining ◽  
Different Types ◽  
Variable Helix

Titanium is difficult-to-cut materials due to its poor machinability and thermal conductivity when machining at high cutting speed. To overcome this machining titanium alloy problem, this study in interaction between machining structural system and the cutting process are very important. One of the main problems in the cutting process is chatter vibration. Due to chatter problem, the mechanism to suppress chatter named, process damping is a useful method can be manipulated to improve the limited productivity of titanium machining at low speed machining in milling process. In the present study, experiment are conducted to evaluate and study the process damping mechanism in milling using different types of variable tools geometries. These tools are variable he-lix/uniform pitch, variable pitch/uniform helix and variable helix and pitch and uniform helix/pitch. The result showed that the variable helix and pitch tools is very significantly improve process damping performance in machining titanium alloy compare to traditional of regular tools and other irregular tools.

Optimization of High Speed Milling Cutter Based on Critical Cutting Speed

2008 ◽  
Vol 392-394 ◽  
pp. 793-797
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Fang Xu
Keyword(s):  
High Speed ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Optimization Method ◽  
Face Milling ◽  
Cutting Performance ◽  
Feed Speed ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Cutting Heat

Based on analyses of cutting heat and temperature in high speed milling, to construct a model of critical cutting speed for high speed milling cutter, find out influencing factor of critical cutting speed, and put forward optimization method of high speed milling cutter based on critical cutting speed. The results indicate that chip conducts a majority of cutting heat along with increase of cutting speed, feed speed and the rake of cutter. Cutting heat which workpiece conducts gradually diminishes when heat source accelerates. When cutting performance of cutter satisfies requirements of high speed milling, the proportion of cutting heat which workpiece conducts approaches its maximum as cutting speed comes to critical cutting speed. To optimize high speed face milling cutter for machining aluminum alloy according to critical cutting speed, the cutter takes on better cutting performance when cutting speed is 2040m/min~2350m/min.

Study of a High Performance AFM Probe-Based Microscribing Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
Keith Bourne ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Tool Wear ◽  
High Performance ◽  
Cutting Speed ◽  
Rake Angle ◽  
Motion Platform ◽  
High Cutting Speed ◽  
Working Volume ◽  
Afm Probe ◽  
Tool Motion ◽  
Five Axis

In this paper, a mechanical microscribing process is described that combines AFM probe-based microscribing with a five-axis microscale machine tool motion platform in order to achieve high scribing speeds, a large working volume, and the capability of cutting curvilinear patterns of grooves. An experiment is described that demonstrates groove formation, groove shape, and tool wear when long grooves are formed using multiple tool passes. A second more systematic experiment is described in which short-distance single-pass cutting tests were used to explore the effects of cutting speed, nominal tool load, and AFM probe mounting angle on groove geometry, tool wear, effective rake angle, and chip formation. Lastly, an experiment is described in which a long curvilinear groove is cut. It is shown that the most well-formed grooves were cut and acceptable tool wear was achieved, when using a high cutting speed, high nominal tool load, and low probe mounting angle. The capability of cutting grooves as long at 82 mm but with depths of only a few hundred nanometers, using a single tool pass at cutting speeds as high at 25 mm/min is demonstrated.

Performance Evaluation of PVD and CVD Coated Inserts during End Milling with DRY and MQL Condition

2017 ◽  
Vol 867 ◽  
pp. 165-170
Author(s):  
Isha Srivastava ◽  
Ajay Batish
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Cutting Operation ◽  
En 31

The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al2O3+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Finite Element Simulation and Experimental Research on Micro-Milling Process of Titanium Alloy

2012 ◽  
Vol 522 ◽  
pp. 245-248 ◽  
Author(s):  
Hai Tao Liu ◽  
Ya Zhou Sun ◽  
De Bin Shan ◽  
Yan Quan Geng
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Simulation ◽  
Large Scale ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Micro Milling ◽  
Element Analysis ◽  
Element Simulation ◽  
Cutting Heat

There are lots of titanium alloy parts which have large-scale micro-structures in astronautic structure and medical implants, so the micro milling becomes one of the effective processing methods in getting the surface micro-structure. Because the titanium alloy has high caking property in processing, it needs a research on the cutting heat and force in order to get better machining precision and surface quality. According to the finite element theory in elastic and plasticity, the influence of cutting speed to the cutting heat and force is got by finite element simulation analysis to the titanium material TC4 in cutting process. It can get the simulation results of cutting heat and force in the micro milling processing by finite element analysis, and then compared, the basic influence which the cutting speed to the cutting heat and force is got. The correctness of the result is checked through cutting experiments.

Evaluation of drilling parameters on surface roughness and burr when drilling carbon black reinforced high-density polyethylene

2018 ◽  
Vol 52 (20) ◽  
pp. 2719-2727 ◽  
Author(s):  
Alper Uysal
Keyword(s):  
Surface Roughness ◽  
Carbon Black ◽  
High Density Polyethylene ◽  
Cutting Speed ◽  
Lower Surface ◽  
High Density ◽  
Effective Parameter ◽  
High Cutting Speed ◽  
Drilling Parameters ◽  
Drill Point

In this study, surface roughness and burr were investigated in drilling of pure and carbon black reinforced high-density polyethylene at three cutting speeds and feeds with three drill point angles. The measurement results of surface roughness of drilled holes were evaluated by Taguchi and analysis of variance statistical methods to specify the optimal drilling parameters and the effects of selected drilling parameters. According to the results, lower surface roughness and fewer burrs were obtained in drilling at high cutting speed and low feed with drill tools having small point angle and it was specified that the carbon black reinforcement reduced the surface roughness. Additionally, the optimal drilling parameters were determined as drill point angle of 80°, feed of 0.1 mm/rev and cutting speed of 120 m/min and the most effective parameter was found as drill point angle and the least effective parameter was found as feed.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

scholarly journals Study on Machinability of Resulfurized Steels under High Cutting Speed (2nd Report)

1987 ◽  
Vol 53 (11) ◽  
pp. 1779-1784
Author(s):  
Yasuo YAMANE ◽  
Biinghwa YAN ◽  
Hitosi USUKI ◽  
Norihiko NARUTAKI
Keyword(s):  
Cutting Speed ◽  
High Cutting Speed

Machinability of BMG

2012 ◽  
Vol 521 ◽  
pp. 225-253
Author(s):  
Mustafa Bakkal
Keyword(s):  
High Temperature ◽  
Metallic Glass ◽  
Viscous Flow ◽  
Bulk Metallic Glass ◽  
Light Emission ◽  
Cutting Speed ◽  
Good Surface ◽  
High Cutting Speed ◽  
Exothermic Chemical Reaction ◽  
Good Surface Roughness

This chapter covers the series of machinability evaluation test result and discussions of Zr52.5Ti5Cu17.9Ni14.6Al10bulk metallic glass (BMG). These tests are lathe turning, drilling, milling and preliminary level grinding tests. In the continuous machining methods such as turning, drilling and grinding of BMG, above a threshold cutting speed, the low thermal conductivity of BMG leads to chip temperatures high enough to cause the chip oxidation and associated light emission. The high temperature produced by this exothermic chemical reaction causes crystallization within the chips. Chips morphology suggests that increasing amounts of viscous flow control the chip-removal process. Moreover, viscous flow and crystallization can occur during the machining of the bulk metallic glass, even under the high temperature gradient and strain rate. High cutting speed significantly reduced the forces for BMG machining due to thermal softening. However, in intermittent cutting process which is milling, there is no high temperature problem, special burr formations the rollover and the top burr were observed along the slot and achieved good surface roughness, Ra= 0.113 μm, using conventional WC-Co cutting tool. In each method, tests repeated for the conventional materials for comparison purpose. This study concludes the precision machining of BMG is possible with the selection of feasible tools and process parameters for each method.

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