A comprehensive experiment-based approach to generate stress field and slip lines in cutting process

2021 ◽  
pp. 1-18
Author(s):  
Zheng-Yan Yang ◽  
Xiao-Ming Zhang ◽  
Guang-Chao Nie ◽  
Dong Zhang ◽  
Han Ding
Keyword(s):  
Stress Field ◽  
Deformation Zone ◽  
Metal Cutting ◽  
Transfer Problem ◽  
Maximum Shear Stress ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Slip Lines ◽  
Strain And Strain Rate ◽  
Main Deformation

Abstract This study proposes a comprehensive experiment-based method to determine stress field and slip lines in metal cutting process. The chip geometry and workpiece's strain and strain rate fields are determined using an in-situ imaging technique. The two-dimensional (2D) heat transfer problem for the steady-state cutting process is solved to derive the cutting temperature, and the flow stresses of work material in the main deformation zone are calculated based on the plasticity theory. Furthermore, the stress field is comprehensively determined to satisfy the stress equilibrium, friction law along the tool-chip interface, and traction-free boundary condition along the uncut chip surface. In addition, slip lines in the main deformation zone are derived according to the direction of maximum shear stress without the assumption of perfect rigid-plastic material. The proposed method is validated by comparing the cutting forces calculated based on the obtained stress field with the experimentally measurements.

Water Vapor Cooling Effects in Turning by Finite Element Modeling

2011 ◽  
Vol 189-193 ◽  
pp. 1631-1634
Author(s):  
Fan Yang ◽  
Jian Long Huang
Keyword(s):  
Finite Element ◽  
Water Vapor ◽  
Geometric Modeling ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Simulation ◽  
Cutting Process ◽  
Finite Element Software ◽  
Aisi 1045 ◽  
Cooling Effects

In order to correctly analyze the effect of water vapor cooling in metal cutting process, the turning process of AISI 1045 in the water vapor cooling condition is simulated using a commercial finite element software Deform-2D, including geometric modeling, meshing, boundary condition setting and material modeling, etc. The cutting temperature in different cooling conditions are then analyzed and discussed. The experimental validation showed a good agreement with simulation results. Thus, FEM simulation of cutting process can be considered as a promising and reliable tool for machining development within the near future.

An analytical modelling of cutting forces in orthogonal elliptical vibration cutting

2020 ◽  
pp. 251659842093613
Author(s):  
Arvind Shivaji Shirale ◽  
Sandeep Sahu ◽  
Sanjeev Kumar Patel ◽  
J. Ramkumar ◽  
Shashank Shekhar
Keyword(s):  
Shear Strength ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Maximum Shear Stress ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Strain And Strain Rate

In the present work, an analytical model is proposed to predict the cutting forces in elliptical vibration cutting (EVC). In general, cutting force in metal cutting is a function of the shear angle ( φ) and shear strength ( τ) of the material. However, these parameters vary dynamically over a cutting cycle of EVC. In this work, the shear angle has been modelled based on the plasticity theory of maximum shear stress criteria. For transient shear strength prediction, the Johnson–Cook model is used. This model predicts shear strength for time-varying strain and strain rate in EVC. The obtained analytical results of cutting forces were compared with experimental results published in the literature and found to be in good agreement (within 12% error) with them. Based on the proposed model, the cutting forces can be modelled as a function of cutting process parameters (depth of cut, cutting velocity), tool parameter (rake angle), physical and thermo-mechanical properties for different materials, without any experimental inputs from EVC.

scholarly journals Modeling of cutting temperature in the biomedical stainless steel turning process

2016 ◽  
Vol 20 (suppl. 5) ◽  
pp. 1345-1354 ◽  
Author(s):  
Dusan Petkovic ◽  
Milos Madic ◽  
Miroslav Radovanovic ◽  
Predrag Jankovic ◽  
Goran Radenkovic
Keyword(s):  
Stainless Steel ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Turning Process ◽  
Infrared Thermal Imaging ◽  
Biomedical Material ◽  
Imaging Camera ◽  
Steel Turning ◽  
The Mathematical Model

Stainless steel is widely used as material in many industries and medicine. As biomedical material, it has been used for making devices, implants as well as tools and equipment in surgery and dentistry. The most of them is processed by turning. Modeling of temperature in the metal cutting process is very important step in understanding and analysis of the metal cutting process. The objective of this study is to develop an artificial neural network model which can be used successfully for accurate prediction of cutting temperature while performing turning of the biomedical stainless steel. Before the modeling, cutting temperature was measured, as one of the significant parameters in turning process, by using the infrared thermal imaging camera. Finally, based on the mathematical model, the effects of the turning parameters on the cutting temperature were examined.

scholarly journals Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis

Micromachines ◽  
2022 ◽  
Vol 13 (1) ◽  
pp. 91
Author(s):  
Shafahat Ali ◽  
Said Abdallah ◽  
Salman Pervaiz
Keyword(s):  
Tool Life ◽  
High Performance ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Cutting Fluids ◽  
Machining Performance

The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

A Finite Element Analysis of Micro/Meso-Scale Machining Considering the Cutting Edge Radius

2007 ◽  
Vol 10-12 ◽  
pp. 631-636 ◽  
Author(s):  
Zi Yang Cao ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Finite Element ◽  
Stress Field ◽  
Size Effect ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Process ◽  
Plastic Deformation Zone ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Meso Scale

In order to investigate the effects of cutting edge radius on micro/meso-scale cutting process, the current paper is concerned with a fundamental investigation of the contribution of cutting edge radius to cutting temperature, stress field and size effect by means of two-dimensional finite-element simulation for orthogonal cutting process. The results indicated that cutting edge radius has remarkable effects on cutting temperature and stress field, and the existence of cutting edge radius is one of the main reasons generating size effect. The cutting edge radius affects the micro/meso scale cutting process at smaller uncut chip thickness by altering the effective rake angle and enhancing the plowing effect, affecting the material deformation process, expanding and widening the plastic deformation zone, and causing higher energy dissipation due to increased tool-chip contact length.

An Inverse Method for Investigating Deformation Zone Temperatures in Metal Cutting

1991 ◽  
Vol 113 (2) ◽  
pp. 129-136 ◽  
Author(s):  
D. A. Stephenson
Keyword(s):  
Deformation Zone ◽  
Inverse Method ◽  
Metal Cutting ◽  
Empirical Studies ◽  
Cutting Temperature ◽  
Steady State Temperature ◽  
Average Deformation ◽  
Thin Walled Tube ◽  
Thin Walled ◽  
Effective Source

A major obstacle in verifying metal cutting temperature models and including thermal variables in empirical studies is the experimental difficulty of measuring physically meaningful cutting temperatures. This is especially true for deformation or shear zone temperatures, which influence the mechanical properties of the work material. This paper describes an inverse method for investigating deformation zone temperatures in end turning tests on thin-walled tubes. The method is based on analytical solutions for the quasi-steady state temperature distributions in a thin-walled ring heated by a rotating temperature source and a thin-walled tube heated by a helically moving source; using these solutions, remote temperature measurements on the tube can be used to back-calculate an effective source temperature which corresponds physically to an average deformation zone temperature. The method has been used in a broad range of experiments on steel, brass, aluminum, and cast iron to verify cutting temperature models. Sample calculations and infrared thermograms from these experiments are used to illustrate the application of the method.

scholarly journals Application of response surface methodology and fuzzy logic based system for determining metal cutting temperature

2016 ◽  
Vol 64 (2) ◽  
pp. 435-445 ◽  
Author(s):  
D. Tanikić ◽  
V. Marinković ◽  
M. Manić ◽  
G. Devedžić ◽  
S. Ranđelović
Keyword(s):  
Response Surface Methodology ◽  
Fuzzy Logic ◽  
Response Surface ◽  
Metal Cutting ◽  
Single Point ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Cutting Regimes

Abstract The heat produced in metal cutting process has negative influence on the cutting tool and the machined part in many aspects. This paper deals with measurement of cutting temperature during single-point dry machining of the AISI 4140 steel, using an infrared camera. Various combinations of cutting parameters, i.e. cutting speed, feed rate and depth of cut lead to different values of the measured cutting temperature. Analysis of the measured data should explain the trends in temperature changes depending on changes in the cutting regimes. Furthermore, the temperature data is modelled using response surface methodology and fuzzy logic. The models obtained should determine the influence of cutting regimes on cutting temperature. The main objective is the reduction of cutting temperature, i.e. enabling metal cutting process in optimum conditions.

Experiment Study of Oil-Air Lubrication on Cooling of Turning Tools

2011 ◽  
Vol 189-193 ◽  
pp. 3187-3190 ◽  
Author(s):  
Jin Li Wang ◽  
Lin Cai ◽  
Hong Tao Zheng
Keyword(s):  
Metal Cutting ◽  
Research Work ◽  
Cutting Temperature ◽  
Cost Savings ◽  
Machining Process ◽  
Dry Cutting ◽  
Air Lubrication ◽  
Temperature Contrast ◽  
Cooling Technology ◽  
Lubrication Conditions

When lubricants are used according to special requirements, it is possible to achieve considerable cost savings. Compared to conventional coolant cooling technology used in metal cutting, oil-air lubrication increases cooling performance, avoids environmental pollution, reduces running and maintenance costs. The cutting temperature contrast experimental research was based on close to practice 45# steel in dry cutting, wet cutting and oil-air lubrication conditions. The research work concentrated on the superiority of oil-air lubrication cooling and the influence of cutting amount on temperature. The experimental results show that oil-air lubrication is more effective in reducing the cutting temperature than wet cutting or dry cutting, this paper details the cutting temperature curves at several different tests provides a basis for industrial production, improves the level of machining process and the significance was being reported.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

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