scholarly journals Development of Thermomechanical Model for the Analysis of Effects of Friction and Cutting Speed on Temperature Distribution around AISI 316L During Orthogonal Machining

2017 ◽  
Vol 7 ◽  
pp. 682-687 ◽  
Author(s):  
Oluseyi O. Ajayi ◽  
Abatan Abiola ◽  
Mercy Ogbonnaya ◽  
Agarana Michael
Keyword(s):  
Temperature Distribution ◽  
Cutting Speed ◽  
Aisi 316L ◽  
Thermomechanical Model ◽  
Orthogonal Machining

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

Microstructural Characterization of Chip Segmentation Under Different Machining Environments in Orthogonal Machining of Ti6Al4V

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Shashikant Joshi ◽  
Asim Tewari ◽  
Suhas S. Joshi
Keyword(s):  
Plastic Strain ◽  
Room Temperature ◽  
Microstructural Analysis ◽  
Cutting Speed ◽  
Microstructural Characterization ◽  
Shear Plane ◽  
Band Formation ◽  
Orthogonal Machining ◽  
Two Temperatures ◽  
Experimental Values

Segmented chips are known to form in machining of titanium alloys due to localization of heat in the shear zone, which is a function of machining environment. To investigate the correlation between machining environments and microstructural aspects of chip segmentation, orthogonal turning experiments were performed under three machining environments, viz., room, LN2, and 260 °C. Scanning electron and optical microscopy of chip roots show that the mechanism of chip segment formation changes from plastic strain and mode II fracture at room temperature, to predominant mode I fracture at LN2 and plastic strain leading to shear band formation at 260 °C. The chip segment pitch and shear plane length predicted using Deform™ matched well with the experimental values at room temperature. The microstructural analysis of chips show that higher shear localization occurs at room temperature than the other two temperatures. The depth of machining affected zone (MAZ) on work surfaces was lower at the two temperatures than that of at the room temperature at a higher cutting speed of 91.8 m/min.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

The Nature of Chip Formation in Orthogonal Machining

1984 ◽  
Vol 106 (1) ◽  
pp. 9-15 ◽  
Author(s):  
Daeyong Lee
Keyword(s):  
Shear Failure ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Test Results ◽  
Mechanical Instability ◽  
Specific Level ◽  
Orthogonal Machining ◽  
Analysis Technique ◽  
Machining Test ◽  
Hardening Coefficient

Orthogonal machining experiments were conducted at the cutting speed of 8.5 × 10−2 cm/s with 6061-T6 aluminum, 4340 steel and Ti-6Al-4V titanium to measure strain distributions in the deformed chip using a grid analysis technique. While the aluminum alloy with low strength and the steel with high strain hardening coefficient displayed large uniform strains with a continuous chip morphology, the titanium alloy exhibited highly nonuniform strain distributions within segmented chips. Some of these observations as well as published machining test results could be rationalized on the basis of a shear failure criterion where a specific level of critical shear strain might be estimated on the basis of a thermal-mechanical instability analysis.

Analytical Model of Progression of Flank Wear Land Width in Drilling

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Ranjan Das ◽  
Suhas S. Joshi ◽  
Harish C. Barshilia
Keyword(s):  
Wear Rate ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Limited Attention ◽  
Orthogonal Machining ◽  
Cutting Velocity ◽  
Temperature Dependent Properties ◽  
Pin On Disk ◽  
Land Width

In multipoint operations like drilling, cutting velocities and cutting-edge geometries vary along cutting lips so is the rate of progression of flank wear. Analytical evaluation of flank wear land width in the case of complex tools has received a limited attention so far. This work evaluates progression of flank wear in orthogonal machining and adopts it to drilling. An abrasive flank wear has been modeled, wherein, cutting speed determines the rate of abrasion, and the feed rate determines the chip load. The model considers stress distribution along rake surfaces, and temperature-dependent properties of tool and work materials. Assuming that the flank wear follows a typical wear progression as in a pin-on-disk test, the model evaluates cutting forces and the consequent abrasive wear rate for an orthogonal cutting. To adopt it to drilling, variation in cutting velocity and dynamic variation in rake, shear, and friction angles along the length of the cutting lips have been considered. Knowing the wear rate, the length of the worn-out flank (vb) has been evaluated. The model captures progression of flank wear in zones (i), (ii), and (iii) of a typical tool-life plot. It marginally underestimates the wear in the rapid wear region and marginally overestimates it in the steady-state region.

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