Design and Analysis of Fluidless Cooling Devices for High Speed Machining

1995 ◽  
Author(s):  
Samir B. Billatos ◽  
Nadia A. Basaly
Keyword(s):  
High Speed ◽  
Surface Characteristics ◽  
Work Piece ◽  
High Speed Machining ◽  
Element Analysis ◽  
New Approach ◽  
Cycle System ◽  
Increase Production Cost ◽  
Harmful Effects ◽  
Interface Heat

Abstract In high speed machining, the generated heat produces very high temperatures at the tool-work interface. Heat generated at the cutting area may shorten tool life, damage work piece surface, affect surface characteristics, and hence increase production cost. To deal with these problems, cutting fluids are used. Unfortunately, these fluids cause harmful effects to the operators and serious problems of pollution to the environment. Therefore, a new approach is developed to reduce the cutting tool temperature without using external coolants, and thus considerably reduce the amount of the hazardous waste being disposed to the environment. It removes a portion of the generated heat from the tool-work interface by flowing water in a closed cooling cycle system. The approach was analyzed and verified using Finite Element Analysis. Results were compared to the dry and wet cutting cases obtained from literature, and it was found that temperatures on the flank and rake faces of the tool can be lowered, and the overheated area of the tool tip, and consequently its wear, can be reduced significantly.

Numerical Simulation of Cutting Force in High Speed Machining of Inconel 718

2020 ◽  
Vol 856 ◽  
pp. 43-49
Author(s):  
Santosh Kumar Tamang ◽  
Nabam Teyi ◽  
Rinchin Tashi Tsumkhapa
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Experimental Result ◽  
Work Piece ◽  
High Speed Machining ◽  
Numerical Result ◽  
3D Software

Machining is one of the major manufacturing processes that converts a raw work piece of arbitrary size into a finished product of definite shape of predetermined size by suitably controlling the relative motion between the tool and the work. Lately, machining process is shifting towards high speed machining (HSM) from conventional machining to improve and efficiently increase production, and towards dry machining from excessive coolant used wet machining to improve economy of production. And the tools used are mostly hardened alloys to facilitate HSM. The work piece materials are continually improving their properties by emergence and development of newer and high resistive super alloys (HRSA). In this paper an attempt has been made to validate an experimental result of cutting force obtained by performing HSM on an HRSA Inconel 718, by comparing it with the numerical result obtained by simulating the same setting using DEFORM 3D software. Based on the comparison it is found that the simulated results exhibit close proximity with the experimental results validating the experimental results and the effectiveness of the software.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

Experimental Investigation and Finite Element Analysis on Electromagnetic Compression Forming Processed Aluminum Alloy Tubes

2011 ◽  
Vol 110-116 ◽  
pp. 1706-1710
Author(s):  
Selvam Rajiv ◽  
Karibeeran Shanmuga Sundaram ◽  
Pablo Pasquale
Keyword(s):  
Experimental Investigation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
High Speed ◽  
High Energy ◽  
Work Piece ◽  
Outer Diameter ◽  
Forming Process ◽  
Element Analysis ◽  
Electromagnetic Compression

Electromagnetic forming (EMF) is a high energy rate forming (HERF) process. It is a high speed forming process using a pulsed magnetic field to form work pieces made of metals such as copper or aluminum alloys with high electrical conductivity. The work piece to be deformed will be located within the effective area of the tool coil so that the resulting type of stress during the forming process is determined by the type of coil used and its arrangement as related to the component. Tubular or structural components can be narrowed by means of compression coils or widened by means of expansion coils, where as sheet metal can be deformed by flat coils. In this work, the experimental investigation and simulation of electromagnetic compression forming of aluminum alloy tubes is studied. The aim of the paper was to verify the results from Finite element methods with experimental data. Experiments were conducted on Tubes of outer diameter 40 mm and wall thickness of 2 mm with a nominal tensile strength of 214 MPa. The tube was compressed using a 4 turn helical actuator discharge that can be energied up to 20 kJ. A field shaper made of aluminum was used. A Maximum reduction of 15.85% in diameters were measured. The same problem was simulated in ANSYS using static coupled electromagnetic analysis. The results of the Simulation showed good correlation with experimental results.

scholarly journals MATING SURFACES MACHINING IN CROSSED CHANNELS

2020 ◽  
Vol 2020 (3) ◽  
pp. 4-10
Author(s):  
Oleg Kirillov ◽  
Vladislav Smolencev ◽  
Evgeniy Kotukov
Keyword(s):  
Electric Field ◽  
High Speed ◽  
Metal Cutting ◽  
Working Environment ◽  
Mathematical Statistics ◽  
Work Piece ◽  
High Speed Machining ◽  
Mathematical Apparatus ◽  
Cutting Equipment ◽  
Selection Of

The purpose of the work is the application of a non-profiled electrode-brush for mating surfaces machining including that in crossed channels. To achieve the goal set there were problems under solution: the development of essential equipment, electrode-tools, the selection of working environment, the optimization of combined machining modes. To solve the problems set there are used basis regulations of the theory: electric and combined methods of machining, the mathematical apparatus of probability theories and mathematical statistics. In the paper the developed and manufactured plants and electrode-tools are shown. The recommended machining conditions, working environment are shown. The equipment is presented with a small-size plant for high-speed machining with an electrode-brush and a portable plant fixed on a drill rod that with the use of operating fluid recommended allows reducing considerably the terms and cost of metal cutting equipment updating for machining with electric field imposition. In the paper there are considered standard parts: nozzles, ejector bodies, parts of piping hydro-systems. The results of machining parts with crossed channels are shown. The application of processing by an electrode-brush with high circumferential velocities with regard to the work-piece from 35 m/sec and higher allows manufacturing products with the set values. The application of an electrode-brush is efficient for mating surfaces combined machining.

An Approach for Continuous Small Line Blocks High Speed Machining of Embedded Systems

2013 ◽  
Vol 842 ◽  
pp. 367-373
Author(s):  
Yao Ting Wang ◽  
Qiu Ju Zhang ◽  
Jin Sai Cheng
Keyword(s):  
Control System ◽  
Embedded Systems ◽  
High Speed ◽  
Processing Time ◽  
Simulation Experiment ◽  
Numerical Control ◽  
High Speed Machining ◽  
New Approach ◽  
Look Ahead ◽  
The Impact

A key issue of the machining for the small line block is to improve the machining feedrate while keeping the machining precision and satisfying the acceleration constraints. In this paper, a new approach for continuous small line blocks high speed machining is proposed to avoid the impact of Computer Numerical Control (CNC) equipments caused by acceleration gust. This approach uses the small line flag to distinguish whether the path is small line block. While the paths are continuous small line blocks, this approach can automatically adjust the number of look-ahead segments, and predigest the velocity calculation method of the connection point. We first define what a path is small line block. Then we analyze the restrictions for velocity linking of adjacent processing paths, and propose the approach for continuous small line blocks machining. Finally we design a simulation experiment on 30 points processing of the spline track. The result of the simulation shows that this algorithm can obviously shorten the processing time and make control system more harmonious in high speed machining.

Research on the Radial Accuracy and Stiffness of HSK Tool System in High Speed Machining

2011 ◽  
Vol 480-481 ◽  
pp. 1335-1340 ◽  
Author(s):  
Chun Jiang Zhou
Keyword(s):  
Finite Element Analysis ◽  
High Speed ◽  
Influence Factor ◽  
High Speed Machining ◽  
Clamping Force ◽  
Key Factors ◽  
Element Analysis ◽  
Positioning Accuracy ◽  
Radial Stiffness ◽  
Elastic Mechanics

The radial positioning accuracy and stiffness are two important indexes to measure the performance of tool system. Once HSK tool system is in operation, the gap between the spindle and shank will enlarge, thus will make the radial positioning accuracy and stiffness lower. The influence factor leading to this problem is analyzed in this paper through elastic mechanics and finite element analysis. It can get from the analysis that the double-position structure and certain amount of interface are key factors to keep HSK high radial positioning accuracy and stiffness. In addition, the influence of clamping force and rotate speed to radial stiffness is presented that higher speed and larger clamping force make the radial stiffness better. Finally, the paper has verified the analysis of radial stiffness through the experimental measurement with different fit of HSK.

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