Boring by Plug-Type Rotary Cutting Tool

1990 ◽  
Vol 112 (2) ◽  
pp. 136-141 ◽  
Author(s):  
K. Yamaguchi ◽  
T. Nakamura ◽  
S. Kato
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Edge ◽  
Machining Accuracy ◽  
Test Results ◽  
Practical Tool ◽  
Rotary Cutting ◽  
Machining Properties ◽  
Tool Rotation

A new boring process is introduced and machining properties are examined. In this process, a drilled hole is finished with a plug-type rotary cutting tool which has a ring-like cutting edge. The plug-type rotary cutting tool is forced into the hole while rotating about the central axis. The effects of the tool rotation on cutting forces and surface finish are experimentally examined, and a practical tool which has a burnishing guide just behind the cutting edge is designed. The machining accuracy of this tool is compared with that of a chucking reamer. Test results show that the inside diameter of the hole finished by the plug-type tool is accurate and stable, even if the tool has an eccentricity.

A Numerical Study to Investigate the Influence of Edge Preparation in Vibration Assisted Machining

2018 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Wael Abdel Samad
Keyword(s):  
Cutting Forces ◽  
Small Amplitude ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Numerical Study ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Internal Stresses ◽  
Machining Performance ◽  
Edge Preparation

In machining operation, cutting tool performs a central role towards the overall machining performance. A user from metal cutting community always look for better cutting tools that can enhance productivity by reducing tool wear and cost. Modification in the micro-geometry of cutting edge is termed as edge preparation, and it is performed to improve the machining performance by strengthening the cutting edge, reducing internal stresses of coating and lowering the edge chipping etc. Edge preparation has a controlling influence on the formation of deformation zones, cutting temperature, cutting forces and stresses at the cutting interface. Vibration assisted machining (VAM) concept is gaining fame in the metal cutting sector community for machining difficult-to-machine materials. In VAM, cutting tool moves with a small amplitude vibration instead of moving with a constant cutting velocity. This small amplitude vibrational movement provides better machining performance for difficult-to-cut brittle materials. The current numerical study utilized different edge prepared micro-geometries such as sharp edge, round edge and chamfer edge etc. cutting tools, and then these cutting tools were used in the numerical simulations of VAM. The study shows higher magnitude of cutting forces under VAM with tools with modified geometry. The study is beneficial for the metal cutting community and opens new areas of industrial applications.

Design and Testing of a Micro-Dynamometer for Desktop Micro-Milling Machine

2014 ◽  
Vol 902 ◽  
pp. 267-273 ◽  
Author(s):  
Samir Mekid
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
High Surface ◽  
Chip Thickness ◽  
Micro Milling ◽  
High Tech ◽  
Machining Accuracy ◽  
Microscopic Features ◽  
Better Than

The emerging miniaturized high-tech products are required to have increased functionalities of systems within a volumetric size on the order of 1 cm3. Hence, the parts are mesoscopic with complex microscopic features of a few mm length with machining accuracy of better than 1 micrometer with secured surface integrity as components will require high surface finish, tensile stress and crack free surfaces in order to function reliably. One of the characteristics to be measured is the cutting forces on the parts being machined. This paper will present the design, manufacture and testing of a miniature dynamometer capable of measuring cutting forces within a low range of 50N but with a resolution better than 1 mN and high frequency since the micromachining involves small cutting forces but the spindle rotates at high speed. The dynamometer is capable of measuring forces in five directions (±x, ±y, and z). The instrument was calibrated and exhibit very good results leading to a true validation. This instrument is assembled on a micro milling desktop machine designed in-house. It will not only support predicting the surface finish and chip thickness but also monitoring tool wear evolution and hence prevents/reduce tool breakage known to be one of the main issues in micro-milling.

Study The Effect of Cutting Conditions (Cutting Speed, Depth of Cut, Feed ) on The Wear of Cutting Tool Bit Turning Machine

2013 ◽  
Vol 1 (2) ◽  
pp. 44-55
Author(s):  
Niema H Elmosawi ◽  
Shalan Gannam Al ◽  
Hamid H. Ali
Keyword(s):  
High Temperature ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Wear Test ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Test Results

The aim of the work is to study the effect of cutting condition on cutting bit of the turning machine while working on different metal ,Through using a special type of commonly used cutting tool bit in (HSS) due to the high qualifications it is characterized by cutting ,and its endurance of high temperature .Two types of metal are used in cutting (Aluminum, Mild steel),relying on the working conditions used in the machine(feed, cutting speed، depth of cut),while conducting working processes via using cooling liquid ,and without it .The wear test results shown that there are two types of wear measured by the (tool micker microscope) :Flank wear and Greater wear, are formed on the cutting edge of the tool bits as a result of the great effect of cutting conditions on the tool bit and the high temperature of the chips ;in addition to the occurrence of resulting edge on the cutting edge of the tool bits in the process of cutting aluminum , with the use of cooling liquids which prolong the of cutting tool and decrease the periods of re-grinding the cutting tool bit. 

Machining analysis of unidirectional and bi-directional flax-epoxy composite laminates

2017 ◽  
Vol 231 (1-2) ◽  
pp. 196-209 ◽  
Author(s):  
J Delahaigue ◽  
J-F Chatelain ◽  
G Lebrun
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
Cutting Forces ◽  
Composite Laminates ◽  
Cutting Tool ◽  
Glass Fibers ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Environmental Benefits ◽  
Synthetic Fibers

Natural fibers, and more particularly, flax fibers, have a considerable potential as replacements for synthetic fibers. These fibers are of significant economic and environmental interest because they are natural products, are biodegradable, and unlike synthetic fibers, are entirely recyclable. They are also less expensive than synthetic fibers, less abrasive for machining, and their specific properties (strength-to-weight ratio) are comparable to those of glass fibers. Consequently, they thus provide economic and environmental benefits for companies. Unfortunately, machining knowledge with respect to this kind of material is low, and research in this domain has barely begun. The objective of this study is to describe the machinability of unidirectional and bidirectional flax/epoxy composites and to analyze the influence of cutting parameters and fiber orientation on cutting forces and surface finish. Milling tests were performed on unidirectional composite laminates with two different tools. The results show that the surface finish and cutting forces depend largely on the feed rate, and to a lesser extent, on the cutting speed. The PCD cutting tool, with a zero helix angle, showed the best performances as compared to the CVD cutting tool, which had a different geometry. The former provided a better surface finish, a lower delamination factor, and lower cutting forces. The material was found to be easy to machine and low abrasive, since no tool wear was observed following the cutting tests. Finally, it was found that an intermediate feed rate value and a high cutting speed were the best of all parameters tested for achieving a low cutting force level, low surface roughness, and high throughput.

Frictional interactions between chip and rake face in continuous chip formation

1979 ◽  
Vol 366 (1725) ◽  
pp. 173-183 ◽  
Keyword(s):  
Cutting Forces ◽  
Single Phase ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Rake Face ◽  
Relative Movement ◽  
Intimate Contact ◽  
Cubic Materials ◽  
Continuous Chip

A transparent sapphire cutting tool is used to study directly the frictional interactions occurring at the chip–tool interface. The investigation deals with the orthogonal cutting of single phase, face-centred cubic materials, in air and in vacuum. The investigation brings out two points of importance. First, although there is intimate contact between the chip and the tool in the immediate vicinity of the cutting edge, there is relative movement at the chip–tool interface with little or no adhesive transfer of chip material in this region. Secondly, in each of the systems examined it was found that oxygen increased the cutting forces. This increase was associated with the gross transfer of chip material onto the cutting tool at some distance away from the cutting edge.

Mechanism of Cutting Force and Surface Generation in Dynamic Milling

1991 ◽  
Vol 113 (2) ◽  
pp. 160-168 ◽  
Author(s):  
D. Montgomery ◽  
Y. Altintas
Keyword(s):  
Cutting Force ◽  
Surface Finish ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Dominant Frequency ◽  
Milling Process ◽  
Cutting Edge ◽  
Surface Generation ◽  
Uncut Chip Thickness ◽  
Improved Model

An improved model of the milling process is presented. The model proposes a method of determining cutting forces in five distinct regions where the cutting edge travels during dynamic milling. Trochoidal motion of the milling cutter is used in determining uncut chip thickness. The kinematics of the cutter and workpiece vibrations are modelled, which identifies the orientation and velocity direction of the cutting edge during dynamic cutting. The model allows the prediction of forces and surface finish under rigid or dynamic cutting conditions. The proposed mechanism of chip thickness, force and surface generation is proven with simulation and experimental results. It is found that when the tooth passing frequency is selected to be an integer ratio of a dominant frequency of tool-workpiece structure in milling imprint of vibrations on the surface finish is avoided.

scholarly journals Cutting Edge Height Measurement of a Rotary Cutting Tool by a Laser Displacement Sensor

2012 ◽  
Vol 6 (6) ◽  
pp. 815-828 ◽  
Author(s):  
Shinichi OSAWA ◽  
So ITO ◽  
Yuki SHIMIZU ◽  
SungHo JANG ◽  
Wei GAO ◽  
...  
Keyword(s):  
Cutting Tool ◽  
Cutting Edge ◽  
Displacement Sensor ◽  
Laser Displacement Sensor ◽  
Height Measurement ◽  
Rotary Cutting

Modeling of cutting parameters in turning of PEEK composite using artificial neural networks and adaptive-neural fuzzy inference systems

2021 ◽  
pp. 089270572110130
Author(s):  
Gökçe Özden ◽  
Mustafa Özgür Öteyaka ◽  
Francisco Mata Cabrera
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Cutting Forces ◽  
Fuzzy Inference ◽  
Test Results ◽  
Inference System ◽  
Good Prediction Accuracy ◽  
Peek Composite ◽  
Artificial Neural ◽  
Neural Fuzzy

Polyetheretherketone (PEEK) and its composites are commonly used in the industry. Materials with PEEK are widely used in aeronautical, automotive, mechanical, medical, robotic and biomechanical applications due to superior properties, such as high-temperature work, better chemical resistance, lightweight, good absorbance of energy and high strength. To enhance the tribological and mechanical properties of unreinforced PEEK, short fibers are added to the matrix. In this study, Artificial Neural Networks (ANNs) and the Adaptive-Neural Fuzzy Inference System (ANFIS) are employed to predict the cutting forces during the machining operation of unreinforced and reinforced PEEK with30 v/v% carbon fiber and 30 v/v% glass fiber machining. The cutting speed, feed rate, material type, and cutting tools are defined as input parameters, and the cutting force is defined as the system output. The experimental results and test results that are predicted using the ANN and ANFIS models are compared in terms of the coefficient of determination ( R2) and mean absolute percentage error. The test results reveal that the ANFIS and ANN models provide good prediction accuracy and are convenient for predicting the cutting forces in the turning operation of PEEK.

Dynamic Analysis and Experimental Research of Laser Cutting Machines

2014 ◽  
Vol 915-916 ◽  
pp. 31-34
Author(s):  
Qing Ping Zhang ◽  
Zheng Ru Wang ◽  
Yan Fang Wang
Keyword(s):  
Machine Tool ◽  
Modal Analysis ◽  
Laser Cutting ◽  
Machining Accuracy ◽  
Dynamics Analysis ◽  
Theoretical Base ◽  
Test Results ◽  
Cutting Machine ◽  
Manufacturing Errors ◽  
Theoretical Results

Vibration is one of the most important problems in laser cutting machine tool, which causes the manufacturing errors, also influences the machining accuracy of the parts. Modal analysis can calculate vibration type of structures. The paper presents how to use the powerful FEA software ANSYS to do the modal analysis on laser cutting machine tool and also studies the undamped free vibration on laser cutting machine tool. Finally, the test results and theoretical results were compared to verify the rationality of the modal, these provide theoretical base and conditions for dynamics analysis and optimal design.

Machinability Evaluation of Inclined Planetary Motion Milling System for Difficult-to-Cut Materials

2015 ◽  
Vol 656-657 ◽  
pp. 320-327 ◽  
Author(s):  
Hidetake Tanaka ◽  
Toma Yoshita
Keyword(s):  
Cutting Tool ◽  
Rotation Axis ◽  
Tool Geometry ◽  
Planetary Motion ◽  
Orbital Drilling ◽  
Drilling Technique ◽  
Cutting Model ◽  
Cutting Experiments ◽  
Tool Rotation ◽  
The Revolution

CFRP and Titanium alloy, which are known as difficult-to-cut materials have been widely used as structural material in aviation industries. The orbital drilling is one of an effective drilling technique for the industries. However this technique has some disadvantages such as increase of cutting force due to cutting with tool center point, inertial vibration generated by revolution and high installation cost. In order to improve the disadvantages, we have invented a new drilling technique which is called inclined planetary motion milling. The inclined planetary motion milling and the planetary mechanism drilling has two axes of cutting tool rotation axis and revolution axis. Cutting tool rotation axis of the orbital drilling is moved parallel to the revolution axis in eccentric. On the other hand, in the case of the inclined planetary motion milling, eccentric of the cutting tool rotation axis is realized by inclination of a few degrees from the revolution axis. Therefore, the movement of eccentric mechanism can be reduced by comparison with the orbital drilling because inclined angle is smaller than eccentricity of the cutting tool tip. As a result, eccentric mechanism can be downsized and inertial vibration is reduced. In the study, a geometrical cutting model of inclined planetary motion milling was set up. The theoretical surface roughness of the inside of drilled holes by use of two types cutting tool geometry were calculated based on the model. And cutting experiments using the new prototype for CFRP were carried out in order to evaluate the effect on machinability with change of cutting point atmosphere. In addition, optimal cutting condition was derived according to cutting experiments for titanium alloys utilizing the orthogonal array.

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