scholarly journals Edge Effect Analysis on orthogonal cutting the Plastic Metal Material-C10100 with Negative Rake Angle Tool

2020 ◽  
Vol 206 ◽  
pp. 02021
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi
Keyword(s):  
Edge Effect ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Contact Friction ◽  
Cutting Condition ◽  
Micro Cutting ◽  
Metal Material ◽  
Edge Radius ◽  
Plastic Metal ◽  
Tool Surface

With the rapid development of the precision grinding and micro-cutting technology, scholars have become more and more interested in the forming mechanism and related characteristics of the rounded-edge tool and the negative rake angle tool. Based on DEFORM-2D forming software, this paper investigates the edge effect of the negative rake angle tool in micro-cutting condition. Through the simulation comparison analysis, it is clear that three deformation regions appear in front of the tool surface, namely the first shear-slip region, the second tool-material contact friction region and the third edge effect deformation region when the negative rake tool cuts the plastic metal material-C10100 with a large edge radius. And a triangle stagnant region appears in front of the tool surface due to the edge effect. By analysing the influence of the ratio of the edge radius to the cutting thickness on the mechanism of orthogonal cutting of negative rake tools, it is found that the minimum cutting thickness value is between

Influence of Reground Tool Sharpness on Micro-Cutting Process

2010 ◽  
Vol 37-38 ◽  
pp. 550-553
Author(s):  
Xin Li Tian ◽  
Zhao Li ◽  
Xiu Jian Tang ◽  
Fang Guo ◽  
Ai Bing Yu
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Cutting Process ◽  
Micro Cutting ◽  
Temperature Distributions ◽  
Edge Radius ◽  
1045 Steel

Tool edge radius has obvious influences on micro-cutting process. It considers the ratio of the cutting edge radius and the uncut chip thickness as the relative tool sharpness (RST). FEM simulations of orthogonal cutting processes were studied with dynamics explicit ALE method. AISI 1045 steel was chosen for workpiece, and cemented carbide was chosen for cutting tool. Sixteen cutting edges with different RTS values were chosen for analysis. Cutting forces and temperature distributions were calculated for carbide cutting tools with these RTS values. Cutting edge with a small RTS obtains large cutting forces. Ploughing force tend to sharply increase when the RTS of the cutting edge is small. Cutting edge with a reasonable RTS reduces the heat generation and presents reasonable temperature distributions, which is beneficial to cutting life. The force and temperature distributions demonstrate that there is a reasonable RTS range for the cutting edge.

On the Size-Effect in Micro-Cutting at Low and High Rake Angles

2004 ◽  
Author(s):  
Sathyan Subbiah ◽  
Shreyes N. Melkote
Keyword(s):  
Size Effect ◽  
Cutting Force ◽  
Constant Width ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Cutting Condition ◽  
Specific Cutting Energy ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Cutting Energy

A partial explanation of the size-effect in the specific cutting energy in micro-cutting is provided in this paper. For a simple orthogonal cutting condition, with constant width of cut, the specific cutting energy is viewed as a ratio of the cutting force and the uncut chip thickness. Size-effect, i.e., an unbounded increase in the specific cutting energy with decrease in uncut chip thickness, will occur under two conditions: one, if a component of the cutting force remains constant with uncut chip thickness and two, if some component of the cutting force increases with the uncut chip thickness. Experiments have been performed at high rake angles in an attempt to isolate and detect the presence of the constant component of the cutting force. The trend confirming the presence of this component is reported and explained.

Analytical cutting force modelling of micro-slot grinding considering tool-workpiece interactions on both primary and secondary tool surfaces

2021 ◽  
pp. 1-43
Author(s):  
Ashwani Pratap ◽  
Karali Patra
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Surface Interactions ◽  
Surface Interaction ◽  
Edge Density ◽  
Force Model ◽  
Height Distribution ◽  
Force Modeling ◽  
Tool Surface

Abstract This work presents an analytical cutting force modeling for micro-slot grinding. Contribution of the work lies in the consideration of both primary and secondary tool surface interactions with the work surface as compared to the previous works where only primary tool surface interaction was considered during cutting force modeling. Tool secondary surface interaction with workpiece is divided into two parts: cutting/ ploughing by abrasive grits present in exterior margin of the secondary tool surface and sliding/adhesion by abrasive grits in the inner margins of the secondary tool surface. Orthogonal cutting force model and indentation based fracture model is considered for cutting by both the abrasives of primary tool surface and the abrasives of exterior margin on the secondary surface. Asperity level sliding and adhesion model is adopted to solve the interaction between the workpiece and the interior margin abrasives of secondary tool surface. Experimental measurement of polycrystalline diamond tool surface topography is carried out and surface data is processed with image processing tools to determine the tool surface statistics viz., cutting edge density, grit height distribution and abrasive grit geometrical measures. Micro-slot grinding experiments are carried out on BK7 glass at varying feed rate and axial depths of cut to validate the simulated cutting forces. Simulated cutting forces considering both primary and secondary tool surface interactions are found to be much closer to the experimental cutting forces as compared to the simulated cutting forces considering only primary tool surface interaction.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

Using Image Analysis Techniques for Single Evaluation of the Chip Shrinkage Factor in Orthogonal Cutting Process

2012 ◽  
Vol 504-506 ◽  
pp. 1329-1334 ◽  
Author(s):  
Moises Batista ◽  
Madalina Calamaz ◽  
Franck Girot ◽  
Jorge Salguero ◽  
Mariano Marcos
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Shrinkage Factor ◽  
A Value ◽  
Chip Shrinkage ◽  
Chip Geometry ◽  
Image Analysis Techniques

The forces involved in a cutting process are related, for example, with the power consumption, with the final quality of the workpiece and with the chip geometry obtained, since these forces determine the compression experimented by the chip and therefore its final geometry. The orthogonal cutting process assisted with a High Speed Filmation (HSF) permit obtains a digital filmation of the process with high magnification. This filmation permits to obtain a measurement of the longitudinal changes produced in the chip. This deforms are related with the Shrinkage Factor, ζ. And in this case the Stabler hypothesis is enabled, by that using the shear angle and the rake angle is possible obtain a value of the Shrinkage Factor in a different conditions.

Effects of diamond cutting tool's rake angle and edge radius on the diamond turned surface quality

2001 ◽  
Author(s):  
Qingliang Zhao ◽  
Shen Dong ◽  
Ying-Chun Liang ◽  
Yi Zhao
Keyword(s):  
Surface Quality ◽  
Rake Angle ◽  
Diamond Cutting ◽  
Edge Radius

The Effect of Prior Cutting Conditions on the Shear Mechanics of Orthogonal Machining

1998 ◽  
Vol 120 (1) ◽  
pp. 13-20 ◽  
Author(s):  
R. Stevenson ◽  
D. A. Stephenson
Keyword(s):  
Material Properties ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cnc Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Prior History ◽  
Machining Conditions ◽  
The Difference

It has been proposed several times in the metal-cutting literature that the machining process is non-unique and that the instantaneous machining conditions depend on the prior machining conditions (e.g. depth of cut, rake angle etc.). To evaluate the validity of this concept, a series of experiments was conducted using a highly accurate CNC machining center. For these experiments, the machining conditions were changed during the course of an orthogonal cutting experiment in a repeatable manner and the measured forces compared as a function of prior history. Tests were conducted on several tempers of 1100 aluminum and commercial purity zinc to evaluate the effect of material properties on the machining response. It was found that the change in measured cutting forces which could be ascribed to prior machining history was less than 3 percent and that material properties, particularly work hardening response, had no discernible effect on the magnitude of the difference.

Sign in / Sign up

Export Citation Format

Share Document