High speed blanking: An experimental method to calculate the induced cutting forces

2009 ◽  
Author(s):  
C. Gaudillière ◽  
N. Ranc ◽  
A. Larue ◽  
P. Lorong
Keyword(s):  
Experimental Method ◽  
Cutting Forces ◽  
High Speed

scholarly journals High Speed Blanking: An Experimental Method to Measure Induced Cutting Forces

2013 ◽  
Vol 53 (7) ◽  
pp. 1117-1126 ◽  
Author(s):  
C. Gaudillière ◽  
N. Ranc ◽  
A. Larue ◽  
A. Maillard ◽  
P. Lorong
Keyword(s):  
Experimental Method ◽  
Cutting Forces ◽  
High Speed

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

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 Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

Forecasting of Cutting Forces in Dental Adjustment of Ceramic Prostheses Using an Artificial Neural Network

2010 ◽  
Vol 152-153 ◽  
pp. 1687-1690
Author(s):  
Jian Hui Peng ◽  
Xiao Fei Song ◽  
Ling Yin
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Process ◽  
Computer Assisted ◽  
Ann Model ◽  
Operational Parameters ◽  
Artificial Neural

Intraoral adjustment of ceramic prostheses involving cutting process is a central procedure in restorative dentistry because the quality of ceramic prostheses depends on the cutting process. In this paper, an artificial neural network (ANN) model was developed for the first time to forecast the dynamic forces in dental cutting process as functions of clinical operational parameters. The predicted force values were compared with the measured values in in vitro dental cutting of porcelain prostheses obtained using a novel two-degrees-of-freedom computer-assisted testing apparatus with a high-speed dental handpiece and diamond burs. The results indicate that there existed nonlinear relationships between the cutting forces and clinical operational parameters. It is found that the ANN-forecasted forces were in good agreement with the experiment-measured values. This indicates that the established ANN model can provide insights into the force-related process assessment and forecast for clinical dental cutting of ceramic prostheses.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Machining Response and Damage Evolution of Amorphous Carbon Coated Tools in High-Speed Micromilling of Ti–6Al–4V

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Rinku K. Mittal ◽  
Salil S. Kulkarni ◽  
Harish Barshilia ◽  
Ramesh Singh
Keyword(s):  
Amorphous Carbon ◽  
Cutting Forces ◽  
Damage Evolution ◽  
Damage Assessment ◽  
High Speed ◽  
Solid Lubricant ◽  
Coated Tools ◽  
Tool Coating ◽  
Carbon Coated ◽  
Cutting Zone

Abstract Micromilling process is widely used to create complex 3D miniature products due to its flexibility and its ability to process difficult-to-cut material like Titanium alloys. High rotational speeds are used to overcome the limited flexural stiffness of the tool but the cutting zone temperatures rise due to the high rotational speeds. In addition to this, friction between the tool workpiece and tool chip also plays a major role in the temperature rise. The friction and temperature affect the cutting forces, tool life and stability of the process. To reduce the friction and heat generation, nanostructured solid lubricant coatings can be used. This study is focused on characterizing the effect of amorphous carbon (WC/a-C) coating on the micromachining response during high-speed micromilling of Ti–6Al–4V. A decrease in cutting forces for coated tools is observed for lower feed. A comprehensive tool coating damage assessment has been done in terms of debonding area on flank and rake faces. An increase in debonding area has been observed with lengths of cut but at a feed/flute of 4 μm, tool breakage occurs after a machining length of 60 mm.

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