scholarly journals Cutting Depth Dictates the Transition from Continuous to Segmented Chip Formation

2021 ◽  
Vol 127 (23) ◽  
Author(s):  
Ramin Aghababaei ◽  
Mohammad Malekan ◽  
Michal Budzik
Keyword(s):  
Chip Formation ◽  
Cutting Depth ◽  
Segmented Chip

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.

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.

scholarly journals Cutting force sensor based on digital image correlation for segmented chip formation analysis

2016 ◽  
Vol 238 ◽  
pp. 466-473 ◽  
Author(s):  
Thomas Baizeau ◽  
Sébastien Campocasso ◽  
Frédéric Rossi ◽  
Gérard Poulachon ◽  
François Hild
Keyword(s):  
Digital Image Correlation ◽  
Cutting Force ◽  
Digital Image ◽  
Chip Formation ◽  
Force Sensor ◽  
Image Correlation ◽  
Segmented Chip

scholarly journals Machinability of Stone—Plastic Materials During Diamond Planing

2019 ◽  
Vol 9 (7) ◽  
pp. 1373 ◽  
Author(s):  
Zhaolong Zhu ◽  
Dietrich Buck ◽  
Xiaolei Guo ◽  
Pingxiang Cao ◽  
Mats Ekevad
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Depth ◽  
Normal Forces ◽  
Plastic Composite ◽  
Chip Shape ◽  
Plastic Materials ◽  
Cutting Heat ◽  
Von Mises

This paper investigated the machinability of a stone–plastic composite (SPC) via orthogonal cutting with diamond cutters. The objective was to determine the effect of cutting depth on its machinability, including cutting forces, heat, chip formation, and cutting quality. Increased cutting depth promoted an increase in both frictional and normal forces, and also had a strong influence on the change in normal force. The cutting temperatures of chips and tool edges showed an increasing trend as cutting depth increased. However, the cutting heat was primarily absorbed by chips, with the balance accumulating in the cutting edge. During chip formation, the highest von Mises strain was mainly found in SPC ahead of the cutting edge, and the SPC to be removed partially passed its elastic limit, eventually forming chips with different shapes. Furthermore, the average surface roughness and the mean peak-to-valley height of machined surfaces all positively correlated to an increase in cutting depth. Finally, with an increase in cutting depth, the chip shape changed from tubular, to ribbon, to arc, to segmental, and finally, to helical chips. This evolution in chip shape reduced the fluctuation in cutting force, improving cutting stability and cutting quality.

A Finite Element Study of Chip Formation Process in Orthogonal Machining

2011 ◽  
Vol 1 (4) ◽  
pp. 19-45 ◽  
Author(s):  
Amrita Priyadarshini ◽  
Surjya K. Pal ◽  
Arun K. Samantaray
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Critical Role ◽  
Fe Model ◽  
Orthogonal Machining ◽  
Adiabatic Shearing ◽  
Segmented Chip ◽  
The Right ◽  
Distribution Of Stress ◽  
Continuous Chip

This paper examines the plane strain 2D Finite Element (FE) modeling of segmented, as well as continuous chip formation while machining AISI 4340 with a negative rake carbide tool. The main objective is to simulate both the continuous and segmented chips from the same FE model based on FE code ABAQUS/Explicit. Both the adiabatic and coupled temperature displacement analysis has been performed to simulate the right kind of chip formation. It is observed that adiabatic hypothesis plays a critical role in the simulation of segmented chip formation based on adiabatic shearing. The numerical results dealing with distribution of stress, strain and temperature for segmented and continuous chip formations were compared and found to vary considerably from each other. The simulation results were also compared with other published results; thus validating the developed model.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: Effect of gradual tool wear evolution

2015 ◽  
Vol 231 (9) ◽  
pp. 1559-1574 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machined Surface ◽  
Segmented Chip ◽  
Gradual Development ◽  
Geometric Variables ◽  
On Chip

Geometric features of the segmented chip have been investigated along with the volume of material removed at a cutting speed at which tool wear is characterized by the gradual development of flank wear when cutting Ti-6Al-4V alloy. The chip geometric variables varied with an increase in the volume of material removed as the combined effect of change in tool’s geometry and increase in cutting temperature. Plastic deformation dimples were observed as periodical regions on the machined surface, a row on each undeformed surface and region on the top of the slipping surface of the segmented chip when cutting with new tool; these dimples on the undeformed surface and machined surface are elongated in the direction of chip flow. All these dimples became less with an increase in the volume of material removed and almost disappeared when the chip was removed with the worn tool at the end of its life. A model of segmented chip formation process has been proposed to satisfactorily explain the formation of the plastic deformation dimples on the undeformed surface and machined surface of the segmented chip produced with a new cutting tool and the transition of chip geometry with the evolution of tool wear.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

scholarly journals Research the chip formation process thermoplastic turning

2020 ◽  
pp. 46-48
Author(s):  
O. YU. Erenkov
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
Experimental Studies ◽  
Polymer Materials ◽  
Cutting Depth ◽  
The Relationship ◽  
Cutting Modes

The article presents the results of experimental studies of the relationship between the characteristics of cutting modes and nature of chip formation for thermoplastics blanks. Caprolon and fl uoroplast-4 were used as the studied materials. It has been experimentally proved that the cutting depth has the maximum eff ect on the chip formation character when turning blanks from the studied polymer materials.

Gezielte Begrenzung der Spandickenschwankungen/Development of a counter element for influencing chip formation when machining titanium. Restriction of chip thickness deviations

2020 ◽  
Vol 110 (11-12) ◽  
pp. 806-810
Author(s):  
Sebastian Berger ◽  
Jannis Saelzer ◽  
Dirk Biermann
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
Tool Life ◽  
Chip Formation ◽  
Chip Thickness ◽  
Vibration Damping ◽  
Suitable Choice ◽  
Periodic Excitation ◽  
Segmented Chip ◽  
Titanium Alloy Ti6al4v

Dieser Beitrag stellt die simulative Analyse zum Einfluss eines begrenzenden Elements zur Unterdrückung der Segmentspanbildung bei der Zerspanung der Titanlegierung Ti6Al4V vor. Dabei lässt sich aufzeigen, dass eine spanbildungsinduzierte periodische Anregung des Systems durch die geeignete Wahl von Geometrie und Positionierung des Elementes verhindert werden kann, wodurch sich die Werkzeugstandzeit und die Oberflächenqualität verbessern und schwingungsdämpfende Maßnahmen obsolet werden. This paper presents the simulative analysis of the influence of a counter element for the suppression of segmented chip formation during the machining of titanium alloy Ti6Al4V. It is shown that a chip formation induced periodic excitation of the system can be prevented by a suitable choice of geometry and positioning of the element, leading to increased tool life and surface quality as well as making vibration damping methods obsolete.

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