Comparison of Rotary and Linear Cutting Methodology in Determining Specific Cutting Energy of Granite

2021 ◽  
pp. 1-19
Author(s):  
Aamer Kazi ◽  
Yi-Tang Kao ◽  
Bruce Tai
Keyword(s):  
Linear Method ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Specific Cutting Energy ◽  
Cnc Machine ◽  
Cutting Method ◽  
Cutting Energy ◽  
The Difference ◽  
Geothermal Drilling ◽  
Chip Load

Abstract Single polycrystalline diamond compact (PDC) cutting is a practical technique to understand the rock-tool interactions in drag-bit type geothermal drilling operations. This paper introduces a rotary cutting method to determine specific cutting energy (SCE) and compares it with the conventional linear cutting method. In this work, granite is selected to represent hard rock formations in geothermal drilling. Cutting tests are conducted on a CNC machine with a realistic cutting speed of 12.7 m/min and several chip loads ranging from 0.08 to 0.25 mm. The cutting force is measured using a dynamometer, and then converted to SCE. The results show that the rotary method produces an inverse relationship between SCE and chip load, whereas the linear method shows the opposite. As a result, the produced SCE by the rotary method tends to be lower than that of the linear method at a higher chip load at and over 0.16 mm. The difference may be attributed to the cutting configuration and associated force components.

Optimization of Cutting Parameters Based on Specific Cutting Energy Consumption for Aluminum 6010 by Using the Analysis of Variance (ANOVA)

2016 ◽  
Vol 842 ◽  
pp. 14-18
Author(s):  
Sri Raharno ◽  
Yatna Yuwana Martawirya ◽  
Heng Rath Visith ◽  
Jeffry Aditya Cipta Wijaya
Keyword(s):  
Energy Consumption ◽  
Analysis Of Variance ◽  
Minimum Energy ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Manufacturing Industries ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Minimum Energy Consumption

Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

scholarly journals Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions

2019 ◽  
Vol 10 (2) ◽  
pp. 561-573 ◽  
Author(s):  
Muhammad Ali Khan ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Younas ◽  
Shahid Ikramullah Butt ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Effective Means ◽  
Sustainable Manufacturing ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Positive Effect

Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Chinmaya R. Dandekar ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Subsurface Damage ◽  
Matrix Composites ◽  
Specific Cutting Energy ◽  
Laser Assisted Machining ◽  
Cutting Energy

Metal matrix composites, due to their excellent properties of high specific strength, fracture resistance, and corrosion resistance, are highly sought after over their nonferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools make the cost associated with machining of these composites very high. This paper is concerned with the machining of high volume fraction long-fiber metal matrix composites (MMCs), which has seldom been studied. The composite material considered for this study is an Al–2% Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al–2% Cu/Al2O3). Laser-assisted machining (LAM) is utilized to improve the tool life and the material removal rate while minimizing the subsurface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, subsurface damage, and tool wear under various material removal temperatures. A multiphase finite element model is developed in ABAQUS/STANDARD to assist in the selection of cutting parameters such as tool rake angle, cutting speed, and material removal temperature. The multiphase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, tool wear rate, and minimum subsurface damage over conventional machining using the same cutting conditions.

Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

2009 ◽  
Author(s):  
Chinmaya R. Dandekar ◽  
Yung C. Shin
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Surface Damage ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Multi Phase

Metal matrix composites due to their excellent properties of high specific strength, fracture resistance and corrosion resistance are highly sought after over their non-ferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools makes the cost associated with machining of these composites very high. This paper is concerned with machining of high volume fraction long-fiber MMC’s, which has seldom been studied. The composite material considered for this study is an Al-2%Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al-2%Cu/Al2O3). Laser-machining is utilized to improve the tool life and the material removal rate while minimizing the sub-surface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, sub-surface damage and tool wear under various material removal temperatures. A multi-phase finite element model is developed in ABAQUS/Standard to identify and assist in selection of cutting parameters such as; tool rake angle, cutting speed and material removal temperature. The multi-phase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, the tool wear rate and minimum sub-surface damage over conventional machining using the same cutting conditions.

Investigations of Nonlinear Forces in Metal Cutting

2006 ◽  
Vol 2 (1-2) ◽  
pp. 59-79 ◽  
Author(s):  
Emily Stone ◽  
Abe Askari ◽  
Hong Tat
Keyword(s):  
Metal Cutting ◽  
Penetration Rate ◽  
Cutting Speed ◽  
Rake Angle ◽  
Type Model ◽  
Vibration Direction ◽  
Effective Rake Angle ◽  
Force Variation ◽  
The Difference ◽  
Chip Load

During chatter in metal cutting the tool vibration would cause a variation in “effective” rake angle of the cutter, generating a force variation that depends on penetration rate: a kind of process damping. This effect is examined for forces computed both from a theoretical Merchant-type model, and from a numerical database of forces for metal cutting constructed from a suite of AdvantEdge simulations. Since the tool can potential vibrate at any angle relative to the workpiece, the forces for varying angle of vibration were computed, and the dynamic stability consequences considered. It is found that the two models lead to similar forces for varying vibration angle, at least through first order. Depending on the vibration angle the force will either increase or decrease with both chip load and penetration rate, reflecting the difference in the effect on the chipload and cutting speed with varying vibration direction. Second order terms in penetration rate were different in the two formulations, possibly a result of approximations used in the calculations involved in the Merchant formulation. Dynamically this means that the linear stability of each vibration angle is the similar for the two models, while the differences in nonlinear terms results in differences in the type Hopf bifurcation observed upon loss of stability.

scholarly journals Specific cutting energy consumption in a circular saw for Eucalyptus stands VM01 and MN463

CERNE ◽  
2011 ◽  
Vol 17 (1) ◽  
pp. 109-115 ◽  
Author(s):  
Erica Moraes de Souza ◽  
José Reinaldo Moreira da Silva ◽  
José Tarcísio Lima ◽  
Alfredo Napoli ◽  
Túlio Jardim Raad ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Specific Energy ◽  
Feed Rate ◽  
Specific Energy Consumption ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Circular Saw ◽  
Cutting Speeds

Modern technologies for continuous carbonization of Eucalyptus sp. require special care in wood cutting procedures. Choosing the right tool, cutting speeds and feed rates is important to manage time and energy consumption, both of which being critical factors in optimizing production. The objective of this work is to examine the influence of machining parameters on the specific cutting energy consumption of Eucalyptus sp. stands MN 463 and VM 01, owned by V&M Florestal. Tests were performed at the Wood Machining Laboratory of the Federal University of Lavras (DCF/UFLA). Moist logs 1.70m in length were used. The experiment was set up using a 3 x 3 x 4 x 2 factorial design (cutting speed x feed rate x number of teeth x tree stand). Results were subjected to analysis of variance and means were compared by the Tukey test at the 5% significance level. Greater cutting speeds, lower feed rates and the 40 teeth circular saw consumed more specific energy. Stand MN 463 consumed more specific energy. The combination of cutting speed 46 m.s-1, feed rate 17 m.min-1 and 24 teeth circular saw produced better specific energy consumption results for stand MN 463. As for stand VM 01, the combination of cutting speed 46 m.s-1, feed rate 17 m.min-1 and 20 teeth circular saw resulted in lower specific energy consumption.

scholarly journals Study of the behavior of sugarcane bagasse submitted to cutting

DYNA ◽  
2015 ◽  
Vol 82 (191) ◽  
pp. 171-175 ◽  
Author(s):  
Nelson Arzola ◽  
Joyner García
Keyword(s):  
Statistical Analysis ◽  
Moisture Content ◽  
Cutting Force ◽  
Sugarcane Bagasse ◽  
Cutting Speed ◽  
Response Surfaces ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Blade Edge ◽  
Pre Treatment

The aim of this work was to study the behavior of sugarcane bagasse submitted to cutting, as a function of its moisture content, angle of the blade edge and cutting speed. The specific cutting energy and peak cutting force were measured using an experimental facility developed for this series of experiments. An analysis of the results of the full factorial experimental design using a statistical analysis of variance (ANOVA) was performed. The response surfaces and empirical models for the specific cutting energy and peak cutting force were obtained using statistical analysis system software. Low angle of the blade edge and low moisture content are, in this order, the most important experimental factors in determining a low specific cutting energy and a low peak cutting force respectively. The best cutting conditions are achieved for an angle of blade edge of 20.8° and a moisture content of 10% w. b. The results of this work could contribute to the optimal design of sugarcane bagasse pre-treatment systems.

scholarly journals Research on cutting performance and fatigue life of conical pick in cutting rock process

2021 ◽  
Vol 104 (4) ◽  
pp. 003685042110502
Author(s):  
Qingliang Zeng ◽  
Zhiwen Wang ◽  
Zhenguo Lu ◽  
Lirong Wan ◽  
Zhihai Liu ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Cutting Force ◽  
Cutting Speed ◽  
Simulation Models ◽  
Cutting Parameters ◽  
Rock Damage ◽  
Specific Cutting Energy ◽  
Conical Pick ◽  
Research Results ◽  
Cutting Energy

The conical pick is the most crucial tool of roadheader for breaking rock, establishing the conical pick cutting rock and conical pick fatigue life numerical simulation models to investigate the influence of cutting parameters on rock damage, average peak cutting force, specific cutting energy and the conical pick fatigue life. The research results indicate that the width and depth of rock damage increase with increasing cutting depth and cutting speed. The average peak cutting force and the specific cutting energy have the same changing tendency. The changing trend of conical pick fatigue life and conical pick stress is opposite relationship. The optimum cutting angle of the conical pick cutting rock is 45°. Applying the research results for guiding the optimization of the cutting parameters reduces the specific cutting energy and stress and improves the conical pick fatigue life.

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