Prediction of Chip Flow Direction, Cutting Forces and Surface Roughness in Finish Turning

1998 ◽  
Vol 120 (1) ◽  
pp. 1-12 ◽  
Author(s):  
J. A. Arsecularatne ◽  
R. F. Fowle ◽  
P. Mathew
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Chip Flow ◽  
Edge Based ◽  
Tool Cutting ◽  
Good Agreement

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and cutting conditions. By defining an equivalent cutting edge based on the chip flow direction it is shown how cutting forces can be predicted under finishing conditions when the work material’s flow stress and thermal properties are known. A comparison between predicted and experimental results obtained for a range of tool geometries and cutting conditions shows good agreement. Surface roughness Ra values measured in the tests are compared with the theoretical values determined from the nose radius and feed.

Prediction of Chip Flow Direction and Cutting Forces in Oblique Machining with Nose Radius Tools

1995 ◽  
Vol 209 (4) ◽  
pp. 305-315 ◽  
Author(s):  
J A Arsecularatne ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Chip Flow ◽  
Wide Range ◽  
Predicted Values ◽  
Edge Based

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and the cutting conditions, namely feed and depth of cut. By defining an equivalent cutting edge based on the chip flow direction it is then shown how cutting forces can be predicted given the work material's flow stress and thermal properties. A comparison between experimental results obtained from bar turning tests and predicted values for a wide range of tool geometries and cutting conditions shows good agreement.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

Allowing for Nose Radius Effects in Predicting the Chip Flow Direction and Cutting Forces in Bar Turning

1987 ◽  
Vol 201 (3) ◽  
pp. 213-226 ◽  
Author(s):  
H T Young ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Excellent Agreement ◽  
Cutting Forces ◽  
Flow Direction ◽  
Experimental Results ◽  
Nose Radius ◽  
Chip Flow ◽  
Bar Turning

A model is presented for predicting the chip flow direction and cutting forces for bar turning with nose radius tools. A comparison which is made of predicted and experimental results shows excellent agreement.

New Chip Flow Angle Prediction to Investigate the Effects of Ratio of the Cutting Edge Lengths on Chip Flow Using Sharp Corner Tools

2011 ◽  
Vol 314-316 ◽  
pp. 1189-1202
Author(s):  
Qing Ming Wang ◽  
Hai Long Lin
Keyword(s):  
Flow Direction ◽  
Current Model ◽  
Fem Simulation ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Sharp Corner ◽  
Flow Angle ◽  
Chip Flow ◽  
Shear Area

Using the basic model of double edge cutting, the minimum value of the total shear area produced by the two cutting edges is calculated to determine the chip flow direction: shearing takes place in the corresponding direction of chip flow to make the shear area minimum under specific cutting parameters with sharp corner tools. The chip flow angle can be obtained using the expression of the variation of the shear area with the chip flow angle. In this study, RATIO is defined as the ratio of the main to the minor cutting edge length engaged in cutting and is set variable on the basis of the constant equivalent cutting area. The chip flow angle corresponding to different values of RATIO predicted by the current model shows good correlation with the experimental measurement and FEM simulation results for various cutting conditions. An investigation of the effects of RATIO on the chip flow angle has been made under various cutting conditions and it is demonstrated that RATIO has a significant influence on the chip flow angle.

Monitoring of Wear Land Width of Diamond Tool Cutting Edge with Large Nose Radius in Ultra-Precision Cutting Using Static Cutting Forces

2014 ◽  
Vol 1017 ◽  
pp. 696-702
Author(s):  
Eiji Kondo ◽  
Ryuichi Iwamoto ◽  
Yuya Kobaru
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Diamond Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Land Width

Large wear of diamond tools for ultra-precision cutting of soft metals deteriorates quality of machined surface, and the worn tools have to be replaced with new tools when the tool wear reaches limited wear land width of cutting edge generating finished surface. However, it is difficult to predict the tool life since all cutting tools have individual tool life. Therefore, the purpose of this study is to estimate wear land width of cutting edge of a single crystal diamond tool having large nose radius by using static cutting forces during machining. As a result of the cutting tests and measurements, it was found that the ratio of thrust force to principal force had good relation with the ratio of flank wear land area to cutting cross section area. Furthermore, according to some detailed observation of flank wear, width of flank wear land was greatly related to uncut chip thickness obtained under different cutting conditions and it was found that width of flank wear land could be estimated by measured static cutting forces and cutting conditions.

Prediction of Cutting Forces and Built-Up Edge Formation Conditions in Machining With Oblique Nose Radius Tools

1996 ◽  
Vol 210 (5) ◽  
pp. 457-469 ◽  
Author(s):  
J A Arsecularatne ◽  
R F Fowle ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Thermal Properties ◽  
Cutting Forces ◽  
Material Flow ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Tool Geometries ◽  
Formation Conditions ◽  
Semi Empirical ◽  
Cutting Speeds ◽  
Good Agreement

A semi-empirical machining theory is described for predicting cutting forces and temperatures for oblique nose radius tools from cutting conditions and a knowledge of work material flow stress and thermal properties. Predictions are made for a range of cutting speeds and tool geometries. It is shown how the cutting conditions giving a built-up edge can be determined from the predicted cutting temperatures. A comparison between predicted and experimental results shows good agreement.

Prediction of Cutting Forces in Milling Stainless Steels using Chamfered Main Cutting Edge Tool

2005 ◽  
Vol 21 (3) ◽  
pp. 145-155 ◽  
Author(s):  
C.-S. Chang
Keyword(s):  
Stainless Steel ◽  
Cutting Forces ◽  
Steel Plate ◽  
Cutting Edge ◽  
304 Stainless Steel ◽  
Workpiece Material ◽  
Material Force ◽  
Force Data ◽  
Edge Tool ◽  
Good Agreement

AbstractTo study the cutting forces, the carbide tip's surface temperature, and the mechanism of secondary chip and main chip formation of face milling stainless steel with a chamfered main cutting edge has been investigated. Theoretical values of cutting forces were calculated and compared to the experimental results with SUS 304 stainless steel plate as a workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. A comparison of the predicted and measured forces shows good agreement. A preliminary discussion is also made for the design of special tool holders and their geometrical configurations. Next, the tips mounted in the tool holders are ground to a chamfered width and the tool dimensions are measured by using a toolmaker microscope.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

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