An Experimental Study of High Speed Orthogonal Cutting

1998 ◽  
Vol 120 (1) ◽  
pp. 169-172 ◽  
Author(s):  
G. Sutter ◽  
A. Molinari ◽  
L. Faure ◽  
J. R. Klepaczko ◽  
D. Dudzinski
Keyword(s):  
Experimental Study ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
High Speed Machining ◽  
Workpiece Material ◽  
Wide Range ◽  
Longitudinal Cutting ◽  
Material Interaction ◽  
Cutting Speeds

A new high speed machining experiment is designed to obtain orthogonal cutting in a wide range of cutting speeds from 7 m/s to 100 m/s. Quasi-stationary cutting conditions are obtained. The measurement of the longitudinal cutting force reveals the existence of an optimal cutting speed for which the energy consumption is minimum. The genuine tool-workpiece material interaction can be analyzed with that experimental device.

Analysis of the Cutting Force Components and Friction in High Speed Machining

2005 ◽  
Vol 127 (2) ◽  
pp. 245-250 ◽  
Author(s):  
G. Sutter ◽  
A. Molinari
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Photographic Recording ◽  
Wide Range ◽  
Cutting Force Components ◽  
Tangential Forces ◽  
Force Components ◽  
Cutting Speeds

An original experimental device is used to reproduce conditions of orthogonal cutting for a wide range of cutting speeds (from 15 to about 100 m/s) (Sutter et al.). Improvement of the initial device (Sutter et al.) makes it possible to record both values of normal and tangential forces in orthogonal cutting. An analysis of the tool–chip friction is then possible for a large range of cutting speeds. The evolution of cutting force components as well as the evolution of the friction coefficient are presented and analyzed. In addition, the process of chip formation during high speed machining is illustrated by photographic recording with a high speed camera.

Investigation of Temperature and Stress Distribution on High Speed Machining of Ti6Al4V and 316L Steel Biomaterials Using Explicit Dynamic Analysis

2017 ◽  
Vol 889 ◽  
pp. 84-89
Author(s):  
Pandithevan Ponnusamy ◽  
Mullapudi Joshi
Keyword(s):  
Dynamic Analysis ◽  
Mechanical Behaviour ◽  
High Speed ◽  
Cutting Speed ◽  
Surgical Instruments ◽  
Interface Temperature ◽  
High Speed Machining ◽  
316L Steel ◽  
Explicit Dynamic ◽  
Cutting Speeds

In high speed machining, to dynamically control the mechanical behaviour of the materials, it is essential to control temperature, stress and strain by appropriate speed, feed and depth of cut. In the present work, to predict the mechanical behaviour of Ti6Al4V and 316L steel bio-materials an explicit dynamic analysis with different cutting speeds was carried out. Orthogonal cutting of 316L steel and Ti6Al4V materials with 720 m/min, 900 m/min and 1200 m/min cutting speeds was performed, and the distribution of stress and temperature was investigated using Jonson-Cook material model. Additionally, the work aimed at determining the effect of cutting speed on work piece temperature, when cutting is carried out continuously. From the investigation, it was found that, while machining Ti6Al4V material, for the increase in cutting speed there was increase in tool-chip interface temperature. Specifically, this could found till the cutting speed 900 m/min. But, there was a decrease in tool-chip interface temperature for the increase in speed from 900 m/min to 1200 m/min. Similarly for 316L steel, the tool-chip interface temperature increased when increasing the cutting speed till 900 m/min. But reduction in temperature from 650 °C to 500 °C for steel and 1028 °C to 990 °C for Ti6Al4V were found, when the cutting speed increased from 900 m/min to 1200 m/min. The study can be used to conclude, at what temperature range the adoption of material with controlled shape and geometry is possible for potential applications like, prosthetic design and surgical instruments prior to fabrications.

Cutting Experiments in Cutting Speeds of up to 200 m/s with a High-Speed Impact Cutting Tester

2012 ◽  
Vol 523-524 ◽  
pp. 1041-1046 ◽  
Author(s):  
Tappei Higashi ◽  
Masato Sando ◽  
Jun Shinozuka
Keyword(s):  
High Speed ◽  
Ambient Pressure ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
High Speed Impact ◽  
Air Gun ◽  
Impact Cutting ◽  
Compressed Gas ◽  
Cutting Experiments ◽  
Cutting Speeds

High-speed orthogonal cutting experiments with cutting speeds of up to 200 m/s with a high-speed impact cutting tester of air-gun type are attempted. In this tester, a light projectile with a small built-in cutting tool is loaded into a tube, being accelerated by a compressed gas. The projectile captures the chip that is indispensable to analyze the cutting mechanism. The projectile holding the chip is decelerated by another compressed gas just after finishing the cutting, being stopped without damage in the tube. Successful experiment can be accomplished by setting adequate values of the operation parameters for the experiment, which are the pressure of each gas and the opening and shutting time of the solenoid-controlled valve for each compressed gas. In order to determine the adequate values of these parameters, a ballistic simulator that simulates the velocity and position of the projectile traveling in the tube is developed. By setting the values of these parameters obtained by the simulator, the cutting speed of 200 m/s is achieved when the ambient pressure is set to be a vacuum and helium is used for each compressed gas. This paper describes the ballistic simulator developed and shows the experimental results of the high-speed cutting of aluminum alloy A2017.

High Speed Machining: A Review from a Viewpoint of Chip Formation

2011 ◽  
Vol 188 ◽  
pp. 578-583 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Masahiro Anzai ◽  
Tsuneo Egawa ◽  
Norihiko Narutaki ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Life Span ◽  
High Speed ◽  
Cutting Speed ◽  
Strong Nonlinearity ◽  
High Speed Machining ◽  
Cast Irons ◽  
Sliding Test ◽  
Cutting Experiments ◽  
Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

MODELING OF THE GRINDING PROCESS BY MICRO-CUTTING SINGLE ABRASIVE GRAINS. PART 1. DETERMINATION OF THE STRENGTH OF ABRASIVE GRAINS

2020 ◽  
pp. 13-17
Author(s):  
Yu. M. Zubarev ◽  
A. V. Priemyshev
Keyword(s):  
Cutting Speed ◽  
Tool Material ◽  
Physical And Mechanical Properties ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Abrasive Grains ◽  
Maximum Cut ◽  
Wide Range ◽  
Cutting Speeds

Main performance indicators of grinding wheels are the strength and wear resistance of abrasive grains. The description of the installation for studying the process of micro-cutting of various materials with single abrasive grains, which allows you to approximate the working conditions of a single abrasive grain to the conditions of real grinding in a wide range of cutting speeds. The effect of the cutting speed on the maximum cut thickness maintained by the grain vertexes without their destruction is shown. The influence of physical and mechanical properties of the workpiece material and the abrasive tool material, together with technological factors, on the micro-cutting process is considered.

scholarly journals A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4074 ◽  
Author(s):  
Víctor Criado ◽  
Norberto Feito ◽  
José Luis Cantero Guisández ◽  
José Díaz-Álvarez
Keyword(s):  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Linear Displacement ◽  
Tool Geometry ◽  
Cfrp Laminates ◽  
Reinforced Plastics ◽  
Wide Range ◽  
Cutting Speeds

Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

Experimental Analysis on Spherical Chips in High-Speed Machining of Hardened AerMet100

2012 ◽  
Vol 723 ◽  
pp. 67-71 ◽  
Author(s):  
Guo Sheng Su ◽  
Zhan Qiang Liu
Keyword(s):  
Formation Mechanism ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Volume Ratio ◽  
Spherical Shape ◽  
High Speed Machining ◽  
Chip Surface ◽  
High Speed Grinding ◽  
Cutting Speeds

Spherical chip appears frequently in high speed grinding of metals. It is attributed to the melt or oxidation of the small chips in grinding. Spherical chip in machining of steels is observed when the cutting speed is high enough. To clarify the formation mechanism of spherical chip in metal cutting, high speed machining of AerMet100 at cutting speeds from 40 m/min to 3000m/min was investigated. Spherical chip of AerMet100 was obtained at cutting speed range 2000-3000m/min. Optical and SEM (Scanning Electron Microscope) observations of the spherical chip was carried out. The chemical composition of the spherical ship was analyzed through X-ray energy dispersive spectroscopy (XEDS) analysis. The formation mechanism of the spherical chip was proposed. The results showed that the spherical shape of chip is due to the intense reaction between Fe of workpiece and O2 in the air accompanying which large mount of heat is released to melt the oxide into small spheres. The formation of the spherical chip is highly influenced by cutting speed and the size of the chip (surface-volume ratio).

Model of Shear Slipping Deformation and its Cutting Energy Consumed for High Speed Machining

2012 ◽  
Vol 602-604 ◽  
pp. 1967-1970 ◽  
Author(s):  
Hu Ping An ◽  
Zhi Yuan Rui ◽  
Rui Feng Wang ◽  
Zhi Mei Zhang
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Shear Velocity ◽  
Shear Instability ◽  
Cutting Condition ◽  
High Speed Machining ◽  
Equilibrium Equations ◽  
Serrated Chip ◽  
Deformation Degree

The characteristics of serrated chips were analyzed using the theory of shear-slipping deformation at high speed cutting, with geometric and mathematic models of the chip built. Deformation of continuous chip for scissile metal materials can be analyzed and controlled by analogous methods that are employed at normal cutting speed. Geometrical model about serrated chip for difficult-to-cut material under orthogonal cutting condition is offered by proper simplifying. The nonlinear equations of indices related to some factors for measuring deformation degree of chip have been ascertained. Based on the condition fo forces equilibrium with respect to single serrated chip at the moment when it is to be in shear instability, forces equilibrium equations are obtained, with shear force and shear velocity as well as friction force and flowing velocity for a chip segment found. Finally, energy equations of cutting are acquired from deformation energy and friction work consumed in the course of chip formation, which can be offered to the further study of mechanism of high speed machining and the design of high speed machine tool.

Experimental Study on Specific Shear Energy in High-Speed Machining 7050-T7451

2013 ◽  
Vol 589-590 ◽  
pp. 8-12
Author(s):  
Guo Sheng Su ◽  
Zhan Qiang Liu
Keyword(s):  
Experimental Study ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Thermal Softening ◽  
High Speed Machining ◽  
Uncut Chip Thickness ◽  
Shear Energy

In this paper, the specific shear energy in high-speed machining 7050-T7451 from 100m/min to 3000m/min is measured and compared with the theoretical value evaluated by the method proposed by Pawade et al. (2009). The influences of cutting speed, rake angle of cutting tool, and uncut chip thickness are also investigated and discussed. Results show that the specific shear energy decreases with the increase of cutting speed, rake angle, and uncut chip thickness. The higher thermal softening makes the specific shear energy lower.

Sign in / Sign up

Export Citation Format

Share Document