Influence of Rock Mechanical Properties on the Formation of Rock Fragments During Cutting Operation

2011 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell
Keyword(s):  
Mechanical Properties ◽  
Cutting Forces ◽  
Numerical Models ◽  
Cutting Parameters ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Fragmentation ◽  
Oil Well ◽  
Explicit Finite Element ◽  
Rock Mechanical Properties

Mechanical rock cutting is a process encountered in different engineering applications including rock excavation, mining and deep oil well drilling. Rock mechanical properties vary with depth in the subsurface and also at different geographical locations due to different environmental conditions. Understanding of fragmentation mechanisms in specific rock materials allows the determination of optimum cutting parameters that improve cutting efficiency and increase tool life during cutting operations. In the present investigation, numerical models that accurately predict the rock fragmentation and stress profiles in the rock slab during cutting were developed using the explicit finite-element method (FEM). In the numerical models, a damage material model was utilized to capture the rock fragmentation process and a rigid steel cutter (at different rake angles) was displaced at different velocities against a stationary rock slab. Rock slabs with significantly different mechanical properties were incorporated with a constant friction factor and a cutting depth of 1 mm. The variation of cutting forces and stresses, and fragmentation of the rock slab were analyzed. The simulation results indicated that the explicit FEM is a powerful tool for simulating rock cutting as the formation of fragments were distinctly observed at different cutting conditions. The rock mechanical properties and tool rake angle were found to have the most significant effect on the rock fragmentation during cutting operations. The cutting forces were also influenced by mechanical properties of the rock and tool rake angle.

Influence of Friction and Rake Angle on the Formation of Discontinuous Rock Fragments During Rock Cutting

2010 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell ◽  
C. Fred Higgs
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Material ◽  
Fragmentation Process ◽  
Rock Fragment ◽  
Explicit Finite Element ◽  
Rock Fragments

Tribological properties during rock cutting under extremely high pressure and high temperature (HPHT) conditions are important in deep mining and drilling operations. In the present investigation, a rock fragmentation process is simulated during mechanical cutting of rock using an explicit finite element code, LS-DYNA. In the simulations, a rigid steel cutting tool of different rake angles was moved at different velocities against a stationary rock material. Rock material properties have been incorporated using an advanced damage constitute material model. In addition, the friction factors at the cutting tool–rock interface were varied in the contact model. The variation of cutting forces, stresses and rock fragment morphology have been investigated. Overall, the results indicate that the explicit finite element model is a powerful tool for simulating rock cutting and the fragmentation process. More specifically, the separation of rock fragments from the rock slab was accurately predicted using the numerical model. The rake angle was found to have significant influence on the fragment morphology during rock cutting. Moreover, the cutting forces and the discontinuous fragmentation process were strongly influenced by the friction and cutting velocity.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Determination of reactional cutting forces on a circular sawblade machine by using experimental studies and numerical modelling

2011 ◽  
Vol 226 (3) ◽  
pp. 775-784 ◽  
Author(s):  
N E Yasitli ◽  
F Bayram ◽  
B Unver ◽  
Y Ozcelik
Keyword(s):  
Numerical Modelling ◽  
Cutting Forces ◽  
Numerical Models ◽  
Experimental Studies ◽  
Cutting Parameters ◽  
Element Model ◽  
Natural Stone ◽  
Processing Plants ◽  
Cutting Operation ◽  
Stone Cutting

Slab/strip production from blocks in natural stone processing plants is mostly carried out by using circular sawblade cutting machines. An efficient sawing operation can only be maintained by selecting proper cutting parameters. Experimental studies and numerical modelling methods are significant in terms of identifying the effective forces occurring during natural stone cutting with circular sawblades. In this study, experimental investigation was performed on real marble, known as Afyon White Marble, using a fully automatic circular sawblade stone cutting machine. Then, numerical modelling of circular sawing was performed with commercially available software called PFC3D. A discrete-element model of the sawing process was developed, and various numerical models were performed for different peripheral speeds and advance rates in compliance with the actual cutting operation being carried out in the laboratory. Finally, data obtained from the experimental studies were compared with the modelling data. A comparison indicates that the reactional cutting forces obtained by means of the numerical modelling are in good agreement with the results of the laboratory measurements. Consequently, the cutting operation can be determined quickly and economically. A literature review showed that, through this study, numerical modelling of the circular sawblade stone cutting process was successfully performed for the first time. It was envisaged that this would dynamically help in the examination of distinct factors in the area of natural stone processing by numerical modelling and in the illustration of the sawing mechanism.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

scholarly journals A study on the influence of pick geometry on rock cutting based on full-scale cutting test and simulation

2020 ◽  
Vol 12 (12) ◽  
pp. 168781402097449
Author(s):  
Xuefeng Li
Keyword(s):  
Shear Failure ◽  
Cutting Parameters ◽  
Rock Cutting ◽  
Rake Angle ◽  
Full Scale ◽  
Cutting Performance ◽  
Tensile Failure ◽  
General Process ◽  
Multiple Attribute ◽  
Cutting Simulations

In this paper, series of full-scale cutting tests and cutting simulations are carried out to investigate the influence of installation parameter and geometry of the pick on cutting performance. The discrete element method is used to simulate the rock cutting process. A general process to calibrate macro properties of rock including uniaxial compressive strength (UCS), elastic modulus, Poisson’s ratio, cohesion and internal friction angle is proposed and used to complete the calibration of coal model. The cutting simulations are performed using picks with different tip angles and rake angles. The results show that the peak cutting force (PCF) decreases with the increase of rake angle following an inverse proportional function when the rake angle is positive, while it varies following a parabolic curve in the condition of negative rake angle. Moreover, the crack mode changes from primarily shear failure to primarily tensile failure with the increase of rake angle. Finally, a multiple-attribute index is proposed to evaluate the cutting performance and select the optimum cutting parameters.

An Explicit Finite Element Model to Study the Influence of Rake Angle on the Discontinuous Chip Formation During Orthogonal Metal Cutting

2009 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell ◽  
Jeen-Shang Lin ◽  
C. Fred Higgs
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Metal Cutting ◽  
Numerical Models ◽  
Rake Angle ◽  
Internal Crack ◽  
Work Piece ◽  
Machining Processes ◽  
Explicit Finite Element ◽  
Orthogonal Metal Cutting

Understanding the tribological aspects of machining processes are essential for increasing the dimensional accuracy and surface integrity of products, as well as gaining a better control of tool wear, chip handling and power consumption. The objective of this investigation is to develop numerical models that accurately predict the chip formation and stress profiles in the work-piece during orthogonal metal cutting using the explicit finite-element method (FEM). In our simulations, a damage material model was utilized to capture the work-piece chip separation behavior and the simultaneous breakage of the chip into multiple fragments. In the simulation, the rigid steel cutter of different rake angles was moved at different velocities against a stationary aluminum work-piece at constant friction for a cutting depth of 1 mm. Overall, the results indicate that the explicit FEM is a powerful tool for simulating metal cutting and discontinuous chip formation. The rake angle had a significant effect on the formation of chip during metal cutting. The formation of discontinuous chip along the contact interface was hypothesized to be due to the internal crack initiation and propagation in front of the tool and above the cutting edge, rather than from the free surface.

Cutting Tool Geometry and Parameters Effects on the Force and Temperature in Turning Steel 1040 Using Finite Element Analysis

2012 ◽  
Vol 548 ◽  
pp. 465-470
Author(s):  
Asaad A. Abdullah ◽  
Usama J. Naeem ◽  
Cai Hua Xiong
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Heat Rate ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Element Analysis

In recent years, applications have been proven finite-element method (FEM) in metal-cutting operations to be effective process in the study of cutting and chip formation. In this study, the simulation results are useful for both researchers and machine tool manufacturers for improving the design of cutting parameters. Finite-element analysis (FEA) that used in this study of simulation the cutting parameters and tool geometries effects on the force and temperature in turning AISI 1040. The simulation parameters that used in this study are cutting speed (75 - 300 m/min),feed rate (0.2 mm/rev), cut depth (0.75-1.5 mm), and rake angle (0-20 °). The results of cutting forces were (240 – 520 N), the temperature were (300-420 °C), and the heat rate (14202.3-83772.8 W/mm3) on the cutting edge. The simulation process also show that the increase of cutting speed leads to decrease in the cutting forces, while it has increasing in temperature, and heat rate. Also, the results show that the increase of cutting depth associated increase the cutting force only.

scholarly journals 2D Finite Element Modeling and Analysis of Dry Turning Process of Aeronautic Aluminium Alloy 2024

2018 ◽  
Vol 7 (4.16) ◽  
pp. 37-41
Author(s):  
Hassan Ijaz ◽  
Waqas Saleem ◽  
Muhammad Asad ◽  
Ahmed Alzahrani ◽  
Tarek Mabrouki
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminium Alloy ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Physical Parameters ◽  
Fe Model ◽  
Element Analysis ◽  
Selection Of

The identification and selection of different physical parameters greatly influence the machining of materials. Cutting speed, feed, tool rake angle and friction are important physical parameters that affect the machining of the materials. Selection of suitable cutting parameters can help to achieve the better machining quality and enhanced tool life. Properly defined FE-model can efficiently simulate the machining processes and thus may help to save the machining cost and expensive materials instead of performing real-life experiments. In the present work, a detailed finite element analysis on the orthogonal cutting of aluminium alloy (AA2024) is conducted to validate the FE-based machining model. Numerically obtained resultant cutting forces are successfully compared with the experimental results for 0.3 and 0.4 mm/rev cutting feeds with 17.5° tool rake angle. Subsequently, the cutting forces are predicted for the selected feeds of 0.35 & 0.45 mm/rev and for different tool rake angles like 9.5°, 13.5° & 21.5° using finite element analysis. Finally, the optimum cutting parameters are suggested for cutting AA2024.           

Finite Element Modeling of the Broaching Process of Inconel718

2011 ◽  
Vol 697-698 ◽  
pp. 39-43 ◽  
Author(s):  
Y. L. Zhang ◽  
Wu Yi Chen
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Area Ratio ◽  
Chip Area ◽  
Element Modeling ◽  
Software Models ◽  
On Chip

2D finite element modeling of the broaching process of Inconel718 was conducted by using the commercial software. Models between cutting forces and cutting parameters were obtained. In addition, a general understanding of the effects of two machining variables rake angle and rising per tooth on chip curling process and gullet-to-chip area ratio, was also obtained.

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