On the Mechanism of Chip Breaking

1979 ◽  
Vol 101 (3) ◽  
pp. 241-249 ◽  
Author(s):  
S. Kaldor ◽  
A. Ber ◽  
E. Lenz
Keyword(s):  
Metal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Production Operation ◽  
Type Ii ◽  
Two Dimensional ◽  
Workpiece Material ◽  
Ductile Materials ◽  
Chip Breaking ◽  
Cutting Operation

During metal cutting while products are being manufactured, the access material is removed in the form of chips. These chips are obtained in various shapes which depend on cutting conditions, type of workpiece material machined, grade of the tool, geometry of cutting, etc. While brittle materials are being machined, the chips are segmental and disintegrating during the chip formation process. Consequently, these chips cause no difficulties. The problem exists when ductile materials are machined and one may observe the following chip forms: I—Long chips—(two dimensional and oblique type); II—Helical chips—(two dimensional and oblique type). These chips were classified by their influence on production operation. Based upon the natural crater developed during the cutting operation a chip breaker groove was introduced. These grooves are pressed into the insert during its manufacturing. It appears that the configuration of the groove has a crucial influence on the range of cutting conditions in which adequate breaking will occur. The presented paper deals with the different machinisms of chip breaking while machining with groove type chip breakers. Tests were carried out to establish the influence of the various parameters, taking part in the cutting operation, on the chip breaking process.

TOOL STRESS PATTERN DEPENDING ON TOOL GEOMETRY

2010 ◽  
Vol 24 (15n16) ◽  
pp. 2792-2796
Author(s):  
YOUNG MOON LEE ◽  
WON SIK CHOI ◽  
JAE HWAN SON ◽  
SUN IL KIM ◽  
HEE CHUL JUNG
Keyword(s):  
Stress Distribution ◽  
Load Distribution ◽  
Metal Cutting ◽  
Tool Material ◽  
Stress Pattern ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Workpiece Material ◽  
Tool Stress ◽  
Material Tool

In metal cutting practices, for a given tool material, tool geometry is a very important element and must be carefully designed in relation to the workpiece material to be machined. Patterns of tool stress are varying with input cutting conditions; however, effects of tool geometry on tool stress are not clearly understood. The load distribution on tool face is affected by the tool geometry and this causes the change of the stress distribution on the tool.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

Modeling and Experimental Analysis of Acoustic Emission from Metal Cutting

1989 ◽  
Vol 111 (3) ◽  
pp. 229-237 ◽  
Author(s):  
R. Teti ◽  
D. Dornfeld
Keyword(s):  
Acoustic Emission ◽  
Experimental Analysis ◽  
Metal Cutting ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Simple Manner ◽  
Work Material ◽  
Theoretical Predictions

Testing parameters characterizing acoustic emission (AE) detected during metal cutting may be theoretically correlated, in a simple manner, to work material properites, cutting conditions, and tool geometry. Experimental results, obtained during turning by different researchers using different AE techniques, are presented and critically assessed with reference to their reciprocal agreement as well as their agreement with theoretical predictions. A review of current methods for AE analysis is also presented and the correlations between different AE parameters and energy and power of the detected signals are reported.

Investigation for High Speed Ultrasonic Cutting of Aluminum Alloy

2012 ◽  
Vol 516 ◽  
pp. 367-372 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Yoshihiro Take ◽  
Toshihiko Koiwa
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Ultrasonic Oscillation ◽  
Workpiece Material ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Cemented Carbide Tool ◽  
Cutting Operation ◽  
Ultrasonic Cutting

This study investigated phenomena of ultrasonic cutting in the case of high-speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in the 1950s. He found a critical cutting speed that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high-speed cutting conditions because the effects of ultrasonic application are cancelled due to tool contacts with the workpiece during the cutting operation. Present ultrasonically assisted cutting cannot allow increased cutting speed because cutting speed is limited by a critical cutting speed that is less than that compared with general cutting speed. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high-speed ultrasonic cutting, and the maximum cutting speed in this research was 300 m/min which is higher than general critical cutting speed. The workpiece material was A5056 and cemented carbide tool inserts were employed in this research. Without ultrasonic oscillation, machined surface retained some built up edge and surface roughness is 28 μmRz. In the case of ultrasonic cutting, surface hasnt built up edge and periodically marks due to ultrasonic oscillation remained on the surface. The roughness of conventionally cut surface is better than in ultrasonic cutting. The cutting phenomena of ultrasonic cutting are different compared with those under conventional cutting conditions.

Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool

1998 ◽  
Vol 120 (1) ◽  
pp. 49-56 ◽  
Author(s):  
B. K. Ganapathy ◽  
I. S. Jawahir
Keyword(s):  
Cutting Force ◽  
Contact Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Two Dimensional ◽  
Cutting Force Model ◽  
Chip Breaking ◽  
Orthogonal Machining

The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

scholarly journals Testing Tool Material on Scratch Tester

2021 ◽  
Vol 9 (12) ◽  
pp. 1926-1930
Author(s):  
Saurav Salunke
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Tool Material ◽  
Workpiece Material ◽  
Research Article ◽  
Base Parameters ◽  
Tool Coating ◽  
Testing Tool ◽  
Cutting Operation

Abstract: In manufacturing industry cutting tools are considered as the backbone of the metal cutting operation. In metal cutting operation there is relative motion between the tool and the workpiece. As the tool material is harder than the workpiece material, there is deformation of the workpiece which acts as a base for the formation of chips. If we observe the process of metal cutting, we can easily find out that there is a considerable amount of heat generated during the machining operation. As there is a point of interface between the tool and the workpiece, there is absorption of generated heat into both the tool as well as work material. Due to the absorption of the heat there is distortion in the tool material. In this research article we have taken the base parameters as speed, load and stroke and the output parameter is taken as the load which breaks the coating of the tool. Keywords: tool coating, scratch tester, speed, stroke, coating.

scholarly journals Optimal Machining Parameters for Achieving the Desired Surface Roughness in Turning of Steel

2012 ◽  
Vol 9 (1) ◽  
pp. 37 ◽  
Author(s):  
LB Abhang ◽  
M Hameedullah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Engineering Sciences

 Due to the widespread use of highly automated machine tools in the metal cutting industry, manufacturing requires highly reliable models and methods for the prediction of output performance in the machining process. The prediction of optimal manufacturing conditions for good surface finish and dimensional accuracy plays a very important role in process planning. In the steel turning process the tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. In the present work, experimental investigations have been conducted to determine the effect of the tool geometry (effective tool nose radius) and metal cutting conditions (cutting speed, feed rate and depth of cut) on surface finish during the turning of EN-31 steel. First and second order mathematical models are developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using LINGO solver programs. LINGO is a mathematical modeling language which is used in linear and nonlinear optimization to formulate large problems concisely, solve them, and analyze the solution in engineering sciences, operation research etc. The LINGO solver program is global optimization software. It gives minimum values of surface roughness and their respective optimal conditions. 

Design of the Intelligent Turning Tool System with Adjustable Tool Geometry

2008 ◽  
Vol 375-376 ◽  
pp. 681-685
Author(s):  
Wen Ge Wu ◽  
Zhan Qiang Liu ◽  
Yun Ping Cheng
Keyword(s):  
Inclination Angle ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Machining Performance ◽  
Oblique Cutting ◽  
Inclination Angles ◽  
Cutting Operation ◽  
Tooling System

The tool geometry such as rake angles and cutting edge inclination angles play significant roles in determining machining performance. The task of selecting cutting tool inserts and cutting conditions is traditionally carried out on the basis of the experience of process planners with the help of data from machining handbooks and tool catalogues. This situation urges the need for development of some intelligent tooling system to reduce these inefficiencies for optimum economic and technological machining performance. A model of turning tool mechanism having the function of controllability in changing the tool inclination angle and tool approach angle is described. The mechanism is realized through the use of three specific slopes which work simultaneously to compensate the tool tip deviation due to the change of inclination angles so that the tool tip always stays at working point in space. Based on the ‘classical’ oblique cutting operation, analytically simulated prediction of the tangential cutting forces were presented with MATLAB software.

Chip Flow and Scaling Laws in High Speed Metal Cutting

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Guy Sutter ◽  
Alain Molinari ◽  
Gautier List ◽  
Xuefeng Bi
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Scaling Laws ◽  
Scaling Law ◽  
Chip Morphology ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Workpiece Material ◽  
Machined Surface ◽  
Perfectly Plastic

Chip formation in machining plays an important role in the cutting process optimisation. Chip morphology often reflects the choice of cutting conditions, the tool wear and by consequences the integrity of the machined surface and tool life. In this study, photographs of the chip morphology during high speed machining of a middle hard steel (C20 similar to AISI 1020) are taken by using a ballistic setup. From these recordings, the evolution of the chip morphology is presented and analysed in terms of cutting conditions. A simplified modeling is then proposed by considering the workpiece material as elastic perfectly plastic. The existence of a scaling law governing the chip morphology in high speed machining is demonstrated. The cutting velocity is shown to have a weak effect at high speed machining as opposed to the well known strong influence of the velocity in the range of low cutting speeds.

Investigation of Cutting Phenomena in High Speed Ultrasonic Turning

2012 ◽  
Vol 523-524 ◽  
pp. 209-214 ◽  
Author(s):  
Keisuke Hara ◽  
Daisuke Hashikai ◽  
Hiromi Isobe ◽  
Jun Ishimatsu ◽  
Yoshihiro Take ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Rake Face ◽  
Workpiece Material ◽  
High Speed Cutting ◽  
Cemented Carbide Tool ◽  
Cutting Operation ◽  
Low Amplitude ◽  
Ultrasonic Cutting

This study investigated phenomena of ultrasonic cutting in case of high speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in 1950’s. He found “critical cutting speed” that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high speed cutting conditions because the effects of ultrasonically applying are canceled due to tool contacts with workpiece during cutting operation. Present ultrasonically assisted cutting cannot increase cutting speed because cutting speed is limited by above reason. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high speed ultrasonic cutting, maximum cutting speed of this research was 160m/min which is higher than general critical cutting speed. Workpiece material is JIS SUS304 stainless steed and cemented carbide tool inserts were employed in this research. In ordinary cutting, generate terrible built up edge on to tool rake face. In case of low amplitude ultrasonic cutting, tool rake face hasn’t built up edge and periodically marks by ultrasonic oscillation were remained on the surface. Cutting phenomena of ultrasonic cutting is different compared with ordinary cutting conditions.

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