Critical rake angle and cutting forces prediction in the orthogonal cutting of polymers

1988 ◽  
Vol 26 (9) ◽  
pp. 1535-1545
Author(s):  
N. N. Z. GINDY
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Rake Angle

Cutting Forces in Orthogonal Cutting of Unidirectional GFRP Composites

1996 ◽  
Vol 118 (3) ◽  
pp. 419-425 ◽  
Author(s):  
G. Caprino ◽  
L. Nele
Keyword(s):  
Size Effect ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Vertical Force ◽  
Fibre Direction ◽  
Unit Width ◽  
Relief Angle

The results of orthogonal cutting tests carried out on unidirectional glass fiber reinforced plastic composites, using HSS tools, are presented and discussed. During the tests, performed on a milling machine at very low cutting speed to avoid thermal effects, the cutting speed was held constant and parallel to the fibre direction. Three parameters, namely the tool rake angle α, the tool relief angle γ, and the depth of cut t, were varied. According to the experimental results, the horizontal force per unit width, Fhu, undergoes a dramatic decrease, never verified for metals, with increasing α. Besides, Fhu is only negligibly affected by the relief angle, and linearly increases with t. Similarly to metals, an effect of the depth of cut on the specific energy (size effect) is found also for composites. However, the presented results indicate that the size effect can be analytically modeled in a simple way in the case of composites. The vertical force per unit width, Fvu, exhibits a marked reduction when the relief angle is increased. Fvu, is also very sensitive to the rake angle: the lower α the higher is Fvu. It is shown that this behavior probably reflects a strong influence of the rake angle on the forces developing at the flank. A linear dependence of the vertical force on the depth of cut is also demonstrated. Finally, the experimental data are utilized to obtain empirical formulae, allowing an approximate evaluation of cutting forces.

Finite Element Simulation of Cutting Forces in Orthogonal Machining of Titanium Alloy Ti-6Al-4V

2014 ◽  
Vol 474 ◽  
pp. 192-199 ◽  
Author(s):  
Ladislav Kandráč ◽  
Ildikó Maňková ◽  
Marek Vrabel' ◽  
Jozef Beňo
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Rake Angle ◽  
Simulation Software ◽  
Tool Geometry ◽  
Element Method

In this paper, a Lagrangian finite element-based machining model is applied in the simulation of cutting forces in two-dimensional orthogonal cutting of titanium Ti-6Al-4V alloy. The simulations were conducted using 2D Finite Element Method (FEM) machining simulation software. In addition, the cutting experiments were carried out under the different cutting speed, feed and tool geometry (rake angle, clearance angle and cutting edge radius). The effect of cutting speed, feed and tool geometry on cutting force were investigated. The results obtained from the finite element method (FEM) and experimental studies were compared.

scholarly journals Fracture energy for orthogonal cutting in unidirectional CFRP at different cutting directions

2022 ◽  
Vol 1217 (1) ◽  
pp. 012011
Author(s):  
A N Amir ◽  
H Ghazali ◽  
H Wang ◽  
L Ye ◽  
N A Fadi ◽  
...  
Keyword(s):  
Fracture Toughness ◽  
Fracture Energy ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Balance Model ◽  
Fracture Mechanisms ◽  
Cutting Depth ◽  
Fibre Direction ◽  
Cfrp Laminate

Abstract A unidirectional carbon fibre reinforced polymer (CFRP) laminate is a composite material made up of strong parallel carbon fibres incorporated in a polymer matrix such as epoxy to provide high stiffness and strength in the fibre direction of the laminate. Unfortunately, the interlaminar or intralaminar plane of this material has a low resistance to damages as the fracture toughness of a unidirectional CFRP laminate is related to the energy dissipation during the orthogonal cutting. The aim of this study is on cutting a unidirectional CFRP along the longitudinal or transverse directions, characterizing orthogonal cutting forces and the related fracture energy. Orthogonal cutting is performed using braised carbide tools for a range of cutting depth of 10-100 ³m with a rake angle of 30° to quantify the cutting forces and to observe the fracture mechanisms. The fibre orientations have a significant impact on surface bouncing-back. For some fibre orientations, the energy balance model is applicable, deducting the reasonable value of fracture toughness due to high normal force (F t). Fibre subsurface damage and cutting forces during cutting are found to be strongly influenced by the cutting depth. The input energy of cutting is released in form of new surface energy, fibre breakage, high bending energy, and chip fracture energy.

SLIP-LINE MODELING OF MACHINING AND DETERMINE THE INFLUENCE OF RAKE ANGLE ON THE CUTTING FORCE

2012 ◽  
Vol 36 (1) ◽  
pp. 23-35 ◽  
Author(s):  
Sabri Ozturk
Keyword(s):  
Cutting Force ◽  
Slip Line ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Thrust Forces ◽  
Model Approach

In this study, the effects of the rake angle on main cutting force (Fc), and thrust forces (Ft) was investigated. A new slip line model approach for modelling the orthogonal cutting process was proposed. This model was applied at negative rake angles from 0° to –60° and consists of three regions. The main forces were measured with a computer aided quick stop device. Variance Analysis (ANOVA) was utilized to analyze the effects of the cutting parameters on cutting and thrust forces accordingly. Multi-variable regression analysis was also employed to determine the correlations between the factors and the cutting forces. The cutting forces could be calculated by equation parameters which are the rake angle and the uncut chip thickness.

RESEARCH ON CUTTING FORCES AND CUTTING TEMPERATURE IN ORTHOGONAL CUTTING SOFTWOOD AND HARDWOOD PARALLEL TO GRAIN

2018 ◽  
Vol 50 (4) ◽  
pp. 458-464
Author(s):  
Xu Bao ◽  
Xiaolei Guo ◽  
Pingxiang Cao ◽  
Linlin Xie ◽  
Minsi Deng
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Temperature

scholarly journals Analytical modelling of cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V

2014 ◽  
Vol 229 (6) ◽  
pp. 1122-1133 ◽  
Author(s):  
Yun Chen ◽  
Huaizhong Li ◽  
Jun Wang
Keyword(s):  
Titanium Alloy ◽  
Cutting Forces ◽  
Chemical Reactivity ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Analytical Modelling ◽  
Shear Instability ◽  
Published Data ◽  
Machining Processes ◽  
Titanium Alloy Ti6al4v

Titanium and its alloys are difficult to machine due to their high chemical reactivity with tool materials and low thermal conductivity. Chip segmentation caused by the thermoplastic instability is always observed in titanium machining processes, which leads to varied cutting forces and chip thickness, etc. This paper presents an analytical modelling approach for cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V. The catastrophic shear instability in the primary shear plane is assumed as a semi-static process. An analytical approach is used to evaluate chip thicknesses and forces in the near-orthogonal cutting process. The shear flow stress of the material is modelled by using the Johnson–Cook constitutive material law where the strain hardening, strain rate sensitivity and thermal softening behaviours are coupled. The thermal equations with non-uniform heat partitions along the tool–chip interface are solved by a finite difference method. The model prediction is verified with experimental data, where a good agreement in terms of the average cutting forces and chip thickness is shown. A comparison of the predicted temperatures with published data obtained by using the finite element method is also presented.

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.

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