Investigations on the Nature of Surface Finish and Its Variation With Cutting Speed

1964 ◽  
Vol 86 (2) ◽  
pp. 134-140 ◽  
Author(s):  
K. L. Chandiramani ◽  
N. H. Cook
Keyword(s):  
Surface Finish ◽  
Chip Formation ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Relative Importance ◽  
Cutting Mechanism ◽  
Low Speed

An attempt has been made to investigate the nature and cause of the variation of surface finish with cutting speed during orthogonal cutting operations. It is found that the variation of cutting speed alone is sufficient to give rise to the three different mechanisms of chip formation, conventionally known as discontinuous, continuous without “bue” (built-up-edge) and continuous with bue. The transition from low-speed, nonbue cutting to high-speed, bue cutting is found to greatly influence the surface finish and in fact the entire cutting mechanism. Photomicrographs of the cutting zones, the chips, and the profiles of the finished surfaces have been taken to observe these changes closely. Tests have also been carried out to determine the relative importance of cutting speed and cutting temperature in affecting the surface finish of the workpiece being machined.

scholarly journals Experimental Investigation on the Cutting Mechanism of Oxygen Free Copper in Cutting Speeds Ranging from 1 m/s to 210 m/s

2013 ◽  
Vol 797 ◽  
pp. 208-213 ◽  
Author(s):  
Jun Shinozuka
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Shear Plane ◽  
Friction Angle ◽  
Temperature Fields ◽  
Cutting Mechanism ◽  
Machined Surface ◽  
High Speed Cutting

The orthogonal cutting tests of oxygen free copper with a cutting speed of from 1 m/s to 210 m/s were performed. The effect of the high-speed cutting on the improvement over the quality of the machined surface, which was evaluated by the thickness of the plastic flow layer and the surface roughness, was examined. By employing the simple shear plane model, the cutting mechanism was analyzed. The results were compared with the results for cutting of aluminum alloy obtained previously. For oxygen free copper, the resultant cutting force does not increase in high-speed cutting. However, the friction angle on the tool-chip interface rises clearly in high-speed cutting. This paper discusses the reason for the increase in the friction angle at the tool-chip interface by investigating the stress and temperature fields on the shear plane and the tool-chip interface.

Chip Formation during Precision Cutting of Metallic Glass

2016 ◽  
Vol 1136 ◽  
pp. 265-270
Author(s):  
Hiroyuki Kodama ◽  
Koichi Okuda ◽  
Tsukasa Inada
Keyword(s):  
Glass Transition ◽  
Transition Temperature ◽  
Glass Transition Temperature ◽  
Metallic Glass ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Shear Angle ◽  
Chip Formation Mechanism

The chip formation mechanism during precision cutting of metallic glass (Zr55Cu30Ni5Al10 at%) was investigated around the glass transition temperature (673 K). Orthogonal cutting of metallic glass are conducted on a fly-cutting machine at various cutting speeds. The new surface of the chips was slightly shiny while the free surface exhibited lamellar slip structure. The cutting temperature was a proportional to the cutting ratio and chip shear angle. The surface integrity worsened with an increased flow of cutting chip due to an increase in the cutting speed. An increase in the cutting temperature caused the chips formation to change from flow type chips to discontinuous chips. When the cutting speed exceeded 300 m/min, the shear angle increased while the shear pitch of the chips decreased. It appears that when the cutting temperature exceeded the glass transition temperature, the strength of the metallic glass decreased and the ductility mode changed due to viscous flow.

scholarly journals MQL Machining with nano fluid: a review

2021 ◽  
Vol 8 ◽  
pp. 13
Author(s):  
Pralhad B. Patole ◽  
Vivek V. Kulkarni ◽  
Sudhir G. Bhatwadekar
Keyword(s):  
Surface Finish ◽  
High Speed ◽  
Metal Cutting ◽  
Experimental Studies ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Work Piece ◽  
Nano Fluid

In any metal cutting machining operation, the cutting fluid plays important role by cooling the cutting tool and the surface of the work piece, also chips are removed from heat affected zone. However, misuse of the cutting fluid and wrong methods of its disposal can affect human health and the environment badly. This paper presents a review of the important research papers published regarding the MQL-based application of mineral oils, vegetable oils and nano fluid-based cutting fluids for different machining processes, such as, drilling, turning, milling and grinding, etc. Most of the experimental studies have shown that application of MQL produces surface better than the flood and dry machining. In turning operation, parameters such as cutting speed, depth of cut, feed rate and tool nose radius have great impact on the surface finish. During high speed turning of steel inherently generates high cutting zone temperature. Such high temperature causes dimensional deviation and failure of cutting tools, surface and subsurface micro cracks, corrosion etc. Therefore, with proper selection of the MQL system and the cutting parameters, it is possible for MQL machining with minimum cost and less quantity of coolant to obtain better conditions, in terms of lubricity, tool life, cutting temperature and surface finish. The findings of this study show that MQL with nano fluid can substitute the flood lubrication for better surface finish.

Experimental and FEM Study of Serrated Chip Formation in High Speed Turning Processes

2011 ◽  
Vol 264-265 ◽  
pp. 1021-1026
Author(s):  
U. Umer ◽  
Li Jing Xie ◽  
Syed Jawid Askari ◽  
S.N. Danish ◽  
S.I. Butt
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Serrated Chip ◽  
High Speed Turning ◽  
Serrated Chip Formation

The finite element method (FEM) has been used to model high speed turning processes with orthogonal cutting conditions. In most of the situations, continuous chip formation is used to analyze the turning process due to its stability and allowing many conditions to simplify the process. However with the increasing applications of high speed turning, serrated chip formation is becoming a more common phenomenon in metal cutting. Serrated chips usually occur in machining of difficult to cut materials at or above a threshold speed. An updated Lagrangian formulation has been used in this study which works with element deletion technique based on a failure criterion. The Johnson Cook strain-hardening thermal-softening material model is used to model serrated chip formation. In addition high speed turning experiments were conducted on AISI H13 tubes using PCBN to analyze serrated chip phenomenon. The chips were analyzed after surface treatment using scanning electron microscope. It has been found that the length of cuts in the chip increases with the cutting speed and the chip changes from serrated to discontinuous. Different process variables like cutting forces, chip morphology, stress, strain and temperature distributions are predicted at different process parameters using FEM. The results show cyclic variation in the cutting forces at high cutting speeds due to varying chip load.

scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

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.

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.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

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