On the Optimized Design of Broaching Tools

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
A. Hosseini ◽  
H. A. Kishawy
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Metal Removal ◽  
Removal Rate ◽  
Geometric Model ◽  
Design Procedure ◽  
Tool Geometry ◽  
Manufacturing Cost ◽  
Force Model ◽  
Optimized Design

Among the cutting tools that are utilized in industry broaching tools are the most expensive ones. Unlike other machining operations such as milling and turning in which a cutting tool can be used for producing a variety of shapes, the broaching tools are uniquely designed depending on the desired profile to be produced on the workpiece. Consequently, the shape of broaching tools may be altered from one case to the others. This shape can be a simple keyway or a complicated fir tree on a turbine disk. Hence, a proper design of the broaching tools has the highest priority in broaching operation. Every single feature of these expensive tools must be accurately designed to increase productivity, promote part quality and reduce manufacturing cost. A geometric model of the cutting tool and a predictive force model to estimate the cutting forces are two fundamental requirements in simulation of any machining operation. This paper presents a geometric model for the broaching tools and a predictive force model for broaching operations. The broaching tooth is modeled as a cantilevered beam and the cutting forces are predicted based on the energy spent in the cutting system. A design procedure has been also developed for identification of the optimized tool geometry aiming to achieve maximum metal removal rate (MRR) by considering several physical and geometrical constraints.

scholarly journals Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

2018 ◽  
Vol 178 ◽  
pp. 01016
Author(s):  
Irina Beşliu ◽  
Dumitru Amarandei ◽  
Delia Cerlincă
Keyword(s):  
Cutting Force ◽  
Tool Steel ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Tool ◽  
End Milling ◽  
Great Influence ◽  
Tool Geometry ◽  
Aisi D2 ◽  
Aisi D2 Tool Steel

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels.

Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics

2000 ◽  
Vol 124 (1) ◽  
pp. 32-41 ◽  
Author(s):  
D. Arola ◽  
M. B. Sultan ◽  
M. Ramulu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Deformable Body ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Tool Geometry ◽  
Reinforced Plastics ◽  
Edge Trimming

A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.

Effects of Electrical Process Parameters and Electrode Tool Geometries in EDM of Inconel825 Material Using Zirconium Copper Electrode

2015 ◽  
Vol 766-767 ◽  
pp. 668-673
Author(s):  
S. Senthamilperarasu ◽  
P. Padmini ◽  
B. Shanmuganathan ◽  
N.R.R. Anbusagar ◽  
P. Sengottuvel
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Metal Removal ◽  
Removal Rate ◽  
Optimization Technique ◽  
Copper Electrode ◽  
Experimental Result ◽  
Tool Geometry ◽  
Zirconium Copper ◽  
Inconel 825

The Electrical Discharge Machine (EDM), parameters are investigated during the machining of Inconel 825 by using different tool geometry of zirconium copper electrode. Demand for better MRR, SR, and lower Tool Wear Rate are increasing recently for all materials, the low rigidity and high material removal rate of Inconel alloy offers a challenging task in obtaining output responses. The analysis of output responses such as Metal Removal Rate (MRR) of Inconel 825 material is carried out an excellent result can be obtained by using Taguchi L16 Orthogonal Array under different conditions of Parameters. The response of MRR is considered for improving machining efficiency. Optimal combination of parameters was obtained Taguchi optimization technique. The confirmation experiments results shows that the significant improvement in output responses was obtained. ANOVA have been used to analyze the contribution of individual parameters on Material Removal Rate. The experimental result demonstrates that the Taguchi method satisfies the practical requirements.

Force Modeling for Generic Profile of Drills

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Kumar Sambhav ◽  
Puneet Tandon ◽  
Sanjay G. Dhande
Keyword(s):  
Cutting Forces ◽  
Arbitrary Point ◽  
Experimental Results ◽  
Tool Geometry ◽  
Force Model ◽  
Force Modeling ◽  
Surface Patches ◽  
Drill Point ◽  
Twist Drills ◽  
Secondary Cutting

The paper presents a methodology to model the cutting forces by twist drills with generic point geometry. A generic definition of point geometry implies that the cutting lips and the relief surfaces can have arbitrary shapes. Such geometry is easily modeled using Non Uniform Rational B-Spline (NURBS) surface patches which give sufficient freedom to the tool designer to alter the tool geometry. The drill point has three cutting zones: primary cutting lips, secondary cutting lips, and the indentation zone at the center of chisel edge. At the indentation zone, the drill extrudes the workpiece, while at the cutting lips, shearing takes place. At primary cutting lip, the cutting is oblique while at secondary cutting lip, it is predominantly orthogonal. Starting from a computer-aided geometric design of a fluted twist drill with arbitrary point profile, the cutting forces have been modeled separately for all the three cutting zones. The mechanistic method has been employed wherever applicable to have a good correlation between the analytical and the experimental results. The force model has been calibrated and validated for conical drills. Then the model has been evaluated for a drill ground with curved relief surfaces. The theoretical and experimental results are found out to be in good conformity.

scholarly journals Force Prediction in Ultrasonic Vibration-Assisted Milling

2019 ◽  
Author(s):  
Yixuan Feng ◽  
Fu-Chuan Hsu ◽  
Yu-Ting Lu ◽  
Yu-Fu Lin ◽  
Chorng-Tyan Lin ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Tool Geometry ◽  
Force Model ◽  
Type I ◽  
Vibration Displacement ◽  
Milling Forces ◽  
Instantaneous Uncut Chip Thickness

Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

Parameter Optimization of Milling Ti6Al4V Using GA Approach

2010 ◽  
Vol 426-427 ◽  
pp. 1-4 ◽  
Author(s):  
Feng Xu ◽  
Jian Jun Zhu ◽  
Xin Wu ◽  
Xiao Jun Zang ◽  
Dun Wen Zuo
Keyword(s):  
Genetic Algorithm ◽  
Titanium Alloy ◽  
Parameter Optimization ◽  
Cutting Tool ◽  
Metal Removal ◽  
Removal Rate ◽  
Metal Removal Rate ◽  
Machined Surface ◽  
Milling Parameters ◽  
Machined Surface Roughness

The research was carried out on the parameter optimization of milling titanium alloy in this paper. The cutting models including cutting force, tool life and machined surface roughness are obtained by orthogonal array experiments. The maximum metal removal rate, MRR is selected as objective function. The constraints related to machine tool, workpiece, cutting tool and other machining situations are presented in details. Genetic algorithm is used to search for the optimum milling parameters for the maximum metal removal rate of titanium alloy. The optimization results show the optimization system can improve the productivity of milling Ti6Al4V obviously.

Modern Metals Machining Technology

1966 ◽  
Vol 88 (1) ◽  
pp. 65-71 ◽  
Author(s):  
Robert L. Vaughn
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Fluid ◽  
Tool Geometry ◽  
Cutter Life ◽  
Cutting Operation

Titanium alloys such as A-110AT, B-120VCA, C-120AV, and 6-6-2AVT, which have been used to manufacture structural components for the aerospace industry, are difficult to machine when compared to aluminum and even some steel alloys. Tool wear for high-speed tool steel and carbide cutters takes place rapidly, necessitating the use of low cutting speeds and feeds to obtain a reasonable cutter life. In this study, the means used toward achieving an objective of increased producibility and reduced costs for titanium alloys was through an intensive machinability investigation of the machining characteristics. Control of pertinent machining variables, such as cutting speed, feed rate, tool material, tool geometry, machine tool setup, and cutting fluid, was rigorously maintained. Comparative cost analyses of the actual cutting operation and the attendant cutting tool costs were made concurrently with the study to obtain conditions which provided the best metal removal rate with reasonable cutter life at the lowest cost.

scholarly journals Modeling of Cutting Forces with a Serrated End Mill

2019 ◽  
Vol 2019 ◽  
pp. 1-13 ◽  
Author(s):  
Yu Guo ◽  
Bin Lin ◽  
Weiqiang Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Geometric Model ◽  
Chip Thickness ◽  
Sine Wave ◽  
Force Model ◽  
End Mill ◽  
Force Coefficients ◽  
Variable Helix ◽  
Milling Forces

The paper presents a mechanistic cutting force model of serrated end mill to predict cutting forces. Geometric model of serrated end mill is established, which covers variable helix end mill geometries. In this model, the serration of helical cutting flutes is expressed spatially and the wave of serration is defined to be a sine wave. The spatial vector is applied to define chip thickness so as to enhance the spatial expressiveness of the model, which is perpendicular to the curvature of each flute. Each helical flute is scatted into a series of infinitesimal cutting edges. The infinitesimal cutting forces depend on three cutting force coefficients and three edge force coefficients in the tangential, radial, and axial directions at every cutting element. By integrating the infinitesimal cutting forces along each cutting edge, the milling forces with serrated end mill can be predicted. The model feasibility of the serrated end mill is verified by comparing the predicted and measured cutting forces. Moreover, the model is also verified such that it can also predict cutting forces with other types of end mills, such as variable helix serrated end mill, variable helix end mill, and regular end mill.

Development of Advanced Broaching Tool for Machining Titanium Alloy

2012 ◽  
Vol 445 ◽  
pp. 161-166
Author(s):  
Mohammed Sarwar ◽  
Mike Dinsdale ◽  
Julfikar Haider
Keyword(s):  
Surface Quality ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Tools ◽  
Vital Role ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Good Surface ◽  
Tool Performance ◽  
Good Surface Finish

Broaching is a precision multipoint metal removal operation normally employed for manufacturing variety of complex parts having either internal or external features. Broaching can produce high precision and good surface finish at a high metal removal rate. The unique feature of a broach tool is that the feed/depth of cut for the teeth is built into the broach unlike other cutting tools. The tool design (e.g., rise per tooth and tooth geometry) play a vital role in the broach performance. A specially adapted machine tool modified to investigate a single broach tooth has been used. Cutting forces and material removal rate have been measured during experimental work for different combination of broaching parameters and broach tool geometry. The effect of the parameters on the surface quality produced has been established. The characteristics of chips formed have also been defined. Finally, optimum tooth geometry and rise per tooth have been recommended for tool performance, broached surface quality and efficient chip formation. The information provided in this paper will be beneficial for broach tool designers and manufacturing engineers.

Dynamic Forces and Hole Quality in Drilling Process

2004 ◽  
Author(s):  
Muge Pirtini ◽  
Ismail Lazoglu
Keyword(s):  
Cutting Forces ◽  
Metal Removal ◽  
Removal Rate ◽  
Drilling Process ◽  
Machining Processes ◽  
Planning Stage ◽  
Cycle Times ◽  
Cutter Deflection ◽  
Home Appliance ◽  
Measured Frequency Response

Drilling is one of the most commonly used machining processes in various industries such as automotive, aircraft and aerospace, dies/molds, home appliance, medical and electronic equipment industries. Due to the increasing competitiveness in the market, cycle times of the drilling processes must be decreased. Moreover, tight geometric tolerance requirements in designs, drilled hole precisions must be increased in production. On the other hand, process engineers have to be conservative when selecting machining conditions with respect to metal removal rate in order to avoid undesirable cases such as drill breakage, excessive cutter deflection and undesirable hole profile problems. In this research, a new mathematical model based on the mechanics and dynamics of the drilling process is developed for the predictions of cutting forces and hole qualities in advance. A new method is also proposed in order to obtain cutting coefficients directly from a set of relatively simple calibration tests. The model is able simulate the cutting forces for various cutting conditions in the process planning stage. In structural dynamics module, measured frequency response functions of the spindle and tool system are integrated into the model in order to obtain drilled hole profiles. Therefore, in addition to predicting the forces, the new model allows to determine and visualize drilled hole profiles in 3D and to select parameters properly under the manufacturing and tolerance constraints. Extensive number of experiments is performed to validate the theoretical model outputs with the measured forces and CMM hole profiles. It is observed that model predictions agree well with the force and CMM measurements. Some of the typical calibration and validation results are presented in this paper.

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