Analytical Modeling of Machining Forces and Friction Characteristics in Ultrasonic Assisted Turning Process

2021 ◽  
pp. 1-13
Author(s):  
Jay Airao ◽  
Chandrakant Kumar Nirala
Keyword(s):  
Analytical Model ◽  
Work Piece ◽  
Contact Ratio ◽  
Friction Characteristics ◽  
Machining Forces ◽  
Ultrasonic Assisted ◽  
Predicted Model ◽  
Ss 304 ◽  
Intermittent Cutting ◽  
Conventional Machining

Abstract Intermittent cutting characteristics of Ultrasonic assisted turning (UAT), Compared to conventional turning (CT), has shown a significant enhancement in the machinability of hard-to-cut materials. The enhancement in machinability is associated with machining forces and friction characteristics of the process. The present article covers an analytical approach to predict the output responses such as machining forces and friction characteristics in UAT and CT processes. Specific cutting energy (SCE) for a particular work-piece material was considered to predict the output responses. The predictions were made by considering the conventional machining theories. Experiments for the UAT and the CT of SS 304 were carried out to validate the predicted model. The results from the analytical model showed that the shear angle increases and the tool-workpiece contact ratio (TWCR) decrease with an increase in amplitude and frequency of vibration. The results obtained from the analytical model were found to be in close agreement with the experimental ones, with an approximate error of 2-20%.

An Experimental Study on the Cutting Forces, Surface Roughness and the Hardness of Al 6061 in 1D and 2D Ultrasonic Assisted Turning

2014 ◽  
Vol 680 ◽  
pp. 224-227 ◽  
Author(s):  
Reza Nosouhi ◽  
Saeed Behbahani ◽  
Saeed Amini ◽  
Mohammad Reza Khosrojerdi
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Detectable Effect ◽  
Work Piece ◽  
Micro Hardness ◽  
Al 6061 ◽  
Hardness Tests ◽  
Ultrasonic Assisted ◽  
Conventional Machining

The machinability of Al 6061 in 1D and 2D ultrasonic assisted turning (UAT) in terms of machining forces, surface roughness and hardness is investigated in this research. In order to perform the machining experiments, a 1D vibration tool and a 2D vibration tool are designed and manufactured. The cutting forces and surface roughness of the work-pieces in 1D UAT and 2D UAT are measured in different cutting speeds and feed rates and compared with that in conventional machining. To investigate the effect of the ultrasonic vibration on the material properties, hardness tests are performed on the work-piece material and micro-hardness tests are carried out on the chip specimens. The results showed that reduction in the cutting forces occurred in UAT. The results also showed that the surface roughness is exceled in UAT in comparison with the conventional machining. While no detectable effect of the ultrasonic vibration on the work-piece material could be observed, the chip micro-hardness experiments showed that the softening phenomenon occurred in UAT, which can be the cause of the force reduction in UAT.

Mechanistic Model of Work-Piece Diametrical Error in Conventional and Ultrasonic Assisted Turning

2012 ◽  
Vol 445 ◽  
pp. 911-916 ◽  
Author(s):  
H. Soleimanimehr ◽  
Mohammad Javad Nategh ◽  
H. Jamshidi
Keyword(s):  
Analytical Model ◽  
Elastic Deformation ◽  
Mechanistic Model ◽  
Experimental Results ◽  
Work Piece ◽  
Force Model ◽  
Deformation Model ◽  
Spring Back ◽  
Ultrasonic Assisted ◽  
Elastic Spring

The spring back is a major source of diametrical error occurring in turning of workpieces. In order to analyze diametrical error, an elastic deflection model of workpiece should be available. Many assumptions are usually taken into consideration when analyzing the elastic deformation of workpiece. Many studies have been done to find the analytical model of work-piece spring back and its suitable cutting force model. When compared with experimental data, developed models in these works are associated with considerable errors. In this paper, through using experimental results, an efficient elastic deformation model of workpiece has been obtained which can be compared with analytical model. Many experiments were performed, and some different functions were produced which predict the trend of experimental results. Finally, an appropriate model with the lowest error was suggested. The same process has been performed in ultrasonic vibrations assisted turning. The obtained functions will be suitable to compensate for the diametrical error occurring by machining forces. Finally this model has been used to obtain the amount of elastic spring back of tool and spindle.

Modeling of residual stresses by correlating surface topography in machining of AISI 52100 steel

2021 ◽  
pp. 1-26
Author(s):  
Chao Liu ◽  
Yan He ◽  
Yufeng Li ◽  
Yulin Wang ◽  
Shilong Wang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Force ◽  
Surface Topography ◽  
Analytical Model ◽  
Analytical Models ◽  
Workpiece Surface ◽  
Dynamic Cutting Force ◽  
Intermittent Cutting ◽  
Effect Of Surface

Abstract The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in analytical model. Then the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of workpiece surface in highest point of the surface topography are higher than that in the lowest point.

Turning Force Prediction of AISI 4130 Considering Dynamic Recrystallization

2017 ◽  
Author(s):  
Zhipeng Pan ◽  
Yixuan Feng ◽  
Xia Ji ◽  
Steven Y. Liang
Keyword(s):  
Grain Size ◽  
Flow Stress ◽  
Dynamic Recrystallization ◽  
Analytical Model ◽  
Cutting Forces ◽  
Material Flow ◽  
Explicit Calculation ◽  
Material Microstructure ◽  
Machining Forces ◽  
Aisi 4130

Thermal mechanical loadings in machining process would promote material microstructure changes. The material microstructure evolution, such as grain size evolution and phase transformation could significantly influence the material flow stress behavior, which will directly affect the machining forces. An analytical model is proposed to predict cutting forces during the turning of AISI 4130 steel. The material dynamic recrystallization is considered through Johnson-Mehl-Avrami-Kolmogorov (JMAK) model. The explicit calculation of average grain size is provided in an analytical model. The grain size effect on the material flow stress is considered by introducing the Hall-Petch relation into a modified Johnson-Cook model. The cutting forces prediction are based on Oxley’s contact mechanics with consideration of mechanical and thermal loads. The model is validated by comparing the predicted machining forces with experimental measurements.

Process Optimization in Non-Conventional Processes

2017 ◽  
pp. 82-119
Author(s):  
Milan Kumar Das ◽  
Tapan Kumar Barman ◽  
Prasanta Sahoo ◽  
Kaushik Kumar
Keyword(s):  
Process Parameters ◽  
Morphological Study ◽  
Artificial Bee Colony ◽  
Removal Rate ◽  
Work Piece ◽  
Bee Colony ◽  
Hard Metals ◽  
Optimal Values ◽  
Grey Relational ◽  
Conventional Machining

Conventional machining becomes non-efficient and non-effective in case of intricate shape and also while working with hard metals and alloys due to excessive tool wear. In such situations non-conventional machining, in contrast becomes more appropriate due to non-contact between tool and work-piece. In the present study, EN31 steel was machined using Plasma Arc Cutting with pre-defined process parameters. Material Removal Rate and Surface roughness were considered as responses for the study. The responses were optimized both as single and multi-response. Considering the complexities of this present problem, experimental data were generated and the results were analyzed by using Taguchi, Grey Relational Analysis and Artificial Bee Colony (ABC) Algorithm. Responses variances with the variation of process parameters were thoroughly studied and analyzed and ‘best optimal values' were identified. The result were verified by the morphological study. It was observed that there was an improvement in responses from mean to optimal values of process parameters.

A Parametric Optimization on Cutting Force during Laser Assisted Machining of Inconel 718 Alloy

2015 ◽  
Vol 787 ◽  
pp. 460-464 ◽  
Author(s):  
M. Vignesh ◽  
K. Venkatesan ◽  
R. Ramanujam ◽  
P. Kuppan
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Inconel 718 ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Work Piece ◽  
Conventional Machining

Inconel 718, a nickel based alloys, addressed as difficult to cut material because of hard carbide particle, hardness, work hardening and low thermal conductivity. Improving the machinability characteristics of nickel based alloys is a major anxiety in aircraft, space vehicle and other manufacturing fields. This paper presents an experimental investigation in Laser assisted turning of Inconel 718 to determine the effects of laser cutting parameters on cutting temperature and cutting forces. This nickel alloy has a material hardness at 48 HRC and machined with TICN/Al2O3/TiN tool. This is employed for the manufacture of helicopter rotor blades and cryogenic storage tanks. The experiments were conducted at One-Factor-at-a-Time.The effects of laser cutting parameters, namely cutting speed, feed rate, laser power and laser to work piece angle, on the cutting temperature and cutting force components, are critically analysed and the results are compared with unassisted machining of this alloy. The experiments are conducted by varying the cutting speed at three levels (50, 75, 100 m/min), feed rate (0.05, 0.075 0.1 mm/rev), laser power (1.25 kW, 1.5 kW, 1.75 kW) and at two level laser to work piece angle (60, 75°). At the optimal parametric combinationof laser power 1.5 kW with cutting speed of 75m/min, feed rate of 0.075 mm/min and laser to work piece angle 60°, the benefit of LAM was shown by 18%, 25% and 24% decrease in feed force (Fx), thrust force (Fy) and cutting force (Fz) as compared to those of the conventional machining. Examination of the machined surface hardness profiles showed no change under LAM and conventional machining.

scholarly journals Modeling of cutting forces in 1-D and 2-D ultrasonic vibration-assisted milling of Ti-6Al-4V

2021 ◽  
Author(s):  
Philipp M. Rinck ◽  
Alpcan Gueray ◽  
Michael F. Zaeh
Keyword(s):  
Cutting Forces ◽  
Friction Reduction ◽  
Cutting Conditions ◽  
Force Model ◽  
Great Effort ◽  
Contact Ratio ◽  
Machining Processes ◽  
Reinforced Plastics ◽  
Frictional Forces ◽  
Intermittent Cutting

AbstractTo meet the modern demands for lightweight construction and energy efficiency, hard-to-machine materials such as ceramics, superalloys, and fiber-reinforced plastics are being used progressively. These materials can only be machined with great effort using conventional machining processes due to the high cutting forces, poor surface qualities, and the associated tool wear. Vibration-assisted machining has already proven to be an adequate solution in order to achieve extended tool lives, better surface qualities, and reduced cutting forces. This paper presents an analytical force model for longitudinal-torsional vibration-assisted milling (LT-VAM), which can predict cutting forces under intermittent and non-intermittent cutting conditions. Under intermittent cutting conditions, the relative contact ratio between the rake face and the sliding chip is utilized for modelling the shearing forces. Ploughing forces and shearing forces under non-intermittent cutting conditions are calculated by using an extended macroscopic friction reduction model, which can predict the reduced frictional forces under parallel and perpendicular vibration superimposition. The force model was implemented in MATLAB and can predict cutting forces without using any experimental vibration-assisted milling (VAM) data input.

Characteristics of Thermo-Electromotive Force, Electric Current and Electric Resistance in Intermittent Cutting Process by Face Milling

2011 ◽  
Vol 314-316 ◽  
pp. 1075-1078 ◽  
Author(s):  
Mitsuaki Murata ◽  
Syuhei Kurokawa ◽  
Osamu Ohnishi ◽  
Toshiro Doi ◽  
Michio Uneda
Keyword(s):  
Tool Wear ◽  
Electric Current ◽  
Electromotive Force ◽  
Flank Wear ◽  
Work Piece ◽  
Electric Resistance ◽  
Tool Flank Wear ◽  
Starting Position ◽  
Process Detection ◽  
Intermittent Cutting

Tool-work thermo-electromotive force (E.M.F.) is very important signal because it is regarded as the evidence of direct cutting phenomenon at the cutting position.Our aim is to carry out in-process monitoring of tool wear under intermittent cutting conditions. We examined the relation between E.M.F. and tool flank wear to explore the possibility of in-process tool wear detection using E.M.F. Waveform variations in E.M.F. signals corresponding to tool flank wear were observed at the starting position of cut. To determine the cause of these waveform variations, the electric current was also measured and the electric resistance between the tool and work piece were calculated using Ohm's law. It is found that the change in the tool-work electric resistance corresponds to the progression of the tool flank wear.By monitoring this tool-work electric resistance, it is possible to conduct in-process detection of tool flank wear.

Analysis of Machinability of Ti- and Ni-Based Alloys

2012 ◽  
Vol 188 ◽  
pp. 330-338 ◽  
Author(s):  
Agostino Maurotto ◽  
Anish Roy ◽  
Vladimir I. Babitsky ◽  
Vadim V. Silberschmidt
Keyword(s):  
Surface Quality ◽  
Cutting Forces ◽  
Material Removal ◽  
Process Zone ◽  
Machining Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Rates ◽  
Conventional Machining

Efficient machining of advanced Ti- and Ni-based alloys, which are typically difficult-to-machine, is a challenge that needs to be addressed by the industry. During a typical machining operation of such alloys, high cutting forces imposed by a tool on the work-piece material lead to severe deformations in the process zone, along with high stresses, strains and temperatures in the material, eventually affecting the quality of finished work-piece. Conventional machining (CT) of Ti- and Ni-based alloys is typically characterized by low depths of cuts and relatively low feed rates, thus adversely affecting the material removal rates (MRR) in the machining process. In the present work, a novel machining technique, known as Ultrasonically Assisted Turning (UAT) is shown to dramatically improve machining of these intractable alloys. The developed machining process is capable of high MRR with an improved surface quality of the turned work-piece. Average cutting forces are significantly lower in UAT when compared to those in traditional turning techniques at the same machining parameters, demonstrating the capability of vibration-assisted machining as a viable machining method for the future.

An Analytical Model for Chemical Etching in One Dimensional Space

2012 ◽  
Vol 445 ◽  
pp. 167-170
Author(s):  
Hossein Amirabadi ◽  
M. Rakhshkhorshid
Keyword(s):  
Analytical Model ◽  
Ferric Chloride ◽  
Chemical Etching ◽  
Dimensional Space ◽  
Etching Rate ◽  
The Other ◽  
Work Piece ◽  
Reaction Parameters ◽  
One Dimensional ◽  
Proposed Model

In this paper an analytical model for chemical etching in one dimensional space has been presented. Regarding to the special specifications of Ferric chloride, etching of an Aluminum work piece exposed to Ferric chloride etchant has been modeled. The proposed model shows that, in the condition of constant reaction parameters, etching rate is a linear function of time. Excellent agreement between the proposed model and the experimental results, published by Çakır (2008), validates the model. By generalization the proposed model, etching rate, or in the other word depth of etch in a specified time, for different materials with different etchants can be predicted.

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