scholarly journals Experimental research of cutting forces during microgrinding

2018 ◽  
Vol 224 ◽  
pp. 01049 ◽  
Author(s):  
Aleksandr Dyakonov ◽  
Anastasia Gorodkova
Keyword(s):  
Experimental Study ◽  
Cutting Force ◽  
Experimental Research ◽  
Cutting Forces ◽  
High Speed ◽  
Narrow Range ◽  
Complex Alloy ◽  
Processed Material ◽  
Metal Materials ◽  
Complex Alloy Steel

In high-speed and heat-stressed processes, the cutting force is a determining parameter of surface quality. The existing studies of the cutting force in microgrinding are experimental and their results are valid for a narrow range of the processed material. The paper describes the experimental study of strength when microgrinding complex alloy steel. The obtained results allow to expand the field of use of micro-grinding technology applied to metal materials.

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%.

Study on Cutting Forces in High-Speed Milling of LF21 Aluminum Alloy and Regression Model of Cutting Forces

2009 ◽  
Vol 69-70 ◽  
pp. 413-417
Author(s):  
Z.H. Wang ◽  
Jun Tan Yuan ◽  
X.Q. Hu ◽  
X.W. Xiong
Keyword(s):  
Regression Model ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Parameters ◽  
Factors Influencing ◽  
Machining Deformation ◽  
Key Factor ◽  
The Right ◽  
Parameter Influence

Cutting force is a key factor influencing the machining deformation of weak rigidity workpieces. In order to reduce the machining deformation and improve the process precision and the surface quality, it is necessary to study the factors influencing the cutting force and build the regression model of cutting forces. Firstly, the cutting parameters influencing cutting force are analyzed for LF21. Secondly, how certain cutting parameter influence the cutting component forces (Fx, Fy, Fz) are studied by the correlation analysis and the approach to choosing the right cutting parameters for machining the weak rigidity workpieces are presented. Finally, the regression model of cutting forces based on the cutting parameters is investigated in this paper.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Cutting Force and Tool Deflection Predictions for High Speed Machining of Hard to Cut Material

2010 ◽  
Vol 154-155 ◽  
pp. 1157-1164 ◽  
Author(s):  
Jinn Jong Sheu ◽  
Dong Mei Xu ◽  
Chin Wei Liu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Force Model ◽  
Beam Model ◽  
High Speed Machining ◽  
Tool Deflection ◽  
Machining Center ◽  
Helical Angle ◽  
Cutting Experiment

The dimension accuracy and the too life are the major issues of the machining of hard-to-cut materials. To fulfill the requirements of accuracy and tool life needs not only well planning of cutting path but also the proper cutting conditions of cutters. The vibration and deflection of cutters caused by poor selection of cutting conditions can be predicted using models of cutting force and tool deflection. In this paper, a cutting force model considering the effect of tool helical angle and a cantilever beam model of tool deflection were proposed for the high speed machining of hard-to-cut material SKD11. The shearing force, the plowing forces, and the helical angle of cutters are considered in the elemental force model. The material of workpiece, SKD11, studied in this paper is commonly used for the die and mold industries. The cutting constants of the proposed force model are determined via the cutting experiments carried out on a high speed machining center. A dynamometer and a high frequency data acquisition system were used to measure the x-, y-, and z-direction cutting forces. The obtained cutting constants were used to predict the cutting forces and compared with the results obtained from the cutting experiment of verification using cutters with different helical angles. The theoretical and the experimental cutting forces in the x-, y-, and z- direction are in good agreement using flat cutters with 30 and 45 degrees of helical angle. The dimension deviations of the cut surface in the cutting experiment case of tool deflection were measured using a touch probe and an infrared receiver installed on the machining center. The measured average dimension deviation, 0.163mm, is close to the predicted tool deflection, 0.153mm, using the proposed cantilever beam model. The comparisons of the cutting forces and the average of the cut surface dimension deviation are in good agreement and verify the proposed cutting force and the tool deflection models are feasible and useful.

Segmented Cutting Coefficient Based Chatter Modeling for High-Speed Micromilling of Ti6Al4V

2016 ◽  
Author(s):  
Kundan K. Singh ◽  
V. Kartik ◽  
Ramesh Singh
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Stability Boundary ◽  
Force Model ◽  
Force Prediction ◽  
High Speeds ◽  
Cutting Coefficients ◽  
Stability Lobe ◽  
Chip Load

Miniature components with complex shape can be created by micromilling with high surface accuracy. However, for difficult-to-machine materials, such as Ti-alloys, failure of low flexural stiffness micro-tools is a big limitation. High spindle speeds (20,000 to 100,000 rpm) can be used to reduce the undeformed chip thickness and the cutting forces and hence the catastrophic failure of the tool can be avoided. This reduced uncut chip thicknesses, in some cases lower than the cutting edge radius, can result in intermittent chip formation which can lead to dynamic variation in cutting forces. These dynamic force variations coupled with low flexural rigidity of micro end mill can render the process unstable. Consequently, accurate prediction of forces and stability is essential in high-speed micromilling. Most of the previous studies reported in the literature use constant cutting coefficients in the mechanistic cutting force model which does not yield accurate results. Recent work has shown significant improvement in the prediction of cutting forces with velocity-chip load dependent coefficients but a single function velocity-chip model fails to predict the forces accurately at very high speeds (>80,000 rpm). This inaccurate force prediction affects the predicted stability boundary at those speeds. Hence, this paper presents a segmented approach wherein a function is fit for a given range of speed to determine the chip load dependent cutting coefficients. The segmented velocity-chip load cutting coefficient improves the cutting force prediction at high speeds. R2 value is found to be improved significantly (>90% for tangential cutting coefficient) which yields the better forces prediction and hence more accurate stability boundary. This paper employs two degrees of freedom (2-DOF) model with forcing functions based on segmented velocity-chip load dependent cutting coefficients. Stability lobe diagram based on 2-DOF model has been created for different speed ranges using Nyquist stability criteria. Chatter frequency ranges between 1.003 to 1.15 times the experimentally determined first modal frequency. Chatter onset has been identified via a laser displacement sensor to experimentally validate the predicted stability lobe.

scholarly journals Taguchi parametric study on the radial and tangential cutting forces in Dry High Speed Machining (DHSM)

10.30544/472 ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 303-316
Author(s):  
M. Hatami ◽  
H. Safari
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Parametric Study ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Machining ◽  
Cutting Speeds

In this paper, L8 Taguchi array is applied to find the most important parameters effects on the radial and tangential cutting forces of a Ti–6Al-4V ELI titanium alloy in dry high speed machining (DHSM). The experiments are performed in four cutting speeds of 150, 200, 250, and 300 m/min and two feed rates of 0.03 and 0.06 mm/rev. Also, two cutting tools in types of XOMX090308TR-ME06 of uncoated (H25) and TiAlN+TiN coated (F40M) are used. Results confirm that to minimize the resultant cutting force and radial cutting force, utilizing the lower feed rate and higher cutting speeds were considered as the best levels of factors to reach to its goal.

THE METHOD OF CALCULATION OF THE CUTTING FORCES BY MACHINING NON–INVOLUTE GEARS GEARS ON THE BASIS OF VIRTUAL EXPERIMENTAL RESEARCHES

2020 ◽  
Vol 2 ◽  
pp. 80-84
Author(s):  
N.V. KANATNIKOV ◽  
P.A. KANATNIKOVA ◽  
A.S. PASHMENTOVA
Keyword(s):  
Cutting Force ◽  
Experimental Research ◽  
Cutting Forces ◽  
Basic Research ◽  
Mechanical Processing ◽  
Method Of Calculation ◽  
Technological Preparation ◽  
Involute Gears ◽  
The Cost ◽  
Experimental Researches

The article shows the possibility of determining the correction coefficients necessary for calculating the cutting force. To calculate the correction coefficients, we use the model of mechanical processing of nonvolvent gears proposed by the authors. Using this approach allows you to eliminate some of the expensive experimental research and reduce the cost of design and technological preparation of production.. This work was supported by the grant of the Russian Foundation for Basic Research No. 18–38–00037 \ 18.

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