Through-Tool Coolant Drilling of Aluminium/SiC Metal Matrix Composite

1999 ◽  
Author(s):  
S. Barnes ◽  
I. R. Pashby
Keyword(s):  
Cutting Forces ◽  
Entry And Exit ◽  
Workpiece Material ◽  
Dry Drilling ◽  
Solid Carbide ◽  
Cutting Operation ◽  
Tool Cooling ◽  
Conventional Cooling ◽  
Tool Cutting

Abstract Through-tool coolant has been applied to the drilling of a 2618 aluminium alloy reinforced with 18% silicon carbide (SiC) particles. Titanium nitride coated, K10, solid carbide drills were used to investigate the effect of the coolant application method on the performance of the drilling operation. Through holes were drilled in a 24 mm thick workpiece material without the application of any coolant, with the conventional application of coolant and with the coolant applied through-the tool. Cutting forces were measured during the drilling trials in addition to the wear on the drills, the extent of the entry and exit burrs produced on the workpiece and the quality of the holes produced. The results obtained provided strong evidence that the conventional application of coolant was having no beneficial effect on the cutting operation compared to dry drilling. However, there was very little evidence of an increase in drill wear which some workers suggest is associated with the formation of an abrasive slurry when using coolant with MMCs. Nevertheless, examination of the used drills in the scanning electron microscope confirmed abrasion as the primary wear mechanism. The results showed mat even at the low coolant pressures, through-tool cooling gave a significant improvement in tool wear, cutting forces, surface finish and the height of the burrs produced. Consequently, the recommendations from this work are that through-tool coolant can result in a marked improvement in performance when drilling MMCs and that conventional cooling has virtually no effect on the machinability of this material compared with dry drilling.

Through-Tool Coolant Drilling of Aluminum/SiC Metal Matrix Composite1

2000 ◽  
Vol 122 (4) ◽  
pp. 384-388 ◽  
Author(s):  
Stuart Barnes ◽  
Ian R. Pashby
Keyword(s):  
Tool Wear ◽  
Beneficial Effect ◽  
Titanium Nitride ◽  
Surface Finish ◽  
Strong Evidence ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Solid Carbide ◽  
Cutting Operation ◽  
Tool Cooling

Through-tool coolant was applied to the drilling of an aluminum/SiC MMC. Titanium nitride coated, solid carbide drills were used to investigate the effect of the coolant application method on the performance of the drilling operation. Holes were produced dry, with conventional coolant and with through-the tool coolant. The results provided strong evidence that the conventional application of coolant was having no beneficial effect on the cutting operation compared to dry drilling. However, through-tool cooling gave a significant improvement in performance in terms of tool wear, cutting forces, surface finish and the height of the burrs produced. [S0094-4289(00)02104-6]

Prediction of Cutting Forces in Milling Stainless Steels using Chamfered Main Cutting Edge Tool

2005 ◽  
Vol 21 (3) ◽  
pp. 145-155 ◽  
Author(s):  
C.-S. Chang
Keyword(s):  
Stainless Steel ◽  
Cutting Forces ◽  
Steel Plate ◽  
Cutting Edge ◽  
304 Stainless Steel ◽  
Workpiece Material ◽  
Material Force ◽  
Force Data ◽  
Edge Tool ◽  
Good Agreement

AbstractTo study the cutting forces, the carbide tip's surface temperature, and the mechanism of secondary chip and main chip formation of face milling stainless steel with a chamfered main cutting edge has been investigated. Theoretical values of cutting forces were calculated and compared to the experimental results with SUS 304 stainless steel plate as a workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. A comparison of the predicted and measured forces shows good agreement. A preliminary discussion is also made for the design of special tool holders and their geometrical configurations. Next, the tips mounted in the tool holders are ground to a chamfered width and the tool dimensions are measured by using a toolmaker microscope.

scholarly journals Analysis of Forces in Vibro-Impact and Hot Vibro-Impact Turning of Advanced Alloys

2011 ◽  
Vol 70 ◽  
pp. 315-320 ◽  
Author(s):  
Riaz Muhammad ◽  
Agostino Maurotto ◽  
Anish Roy ◽  
Vadim V. Silberschmidt
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Strain Rates ◽  
Machining Processes ◽  
Machined Surface ◽  
Cutting Zone

Analysis of the cutting process in machining of advanced alloys, which are typically difficult-to-machine materials, is a challenge that needs to be addressed. In a machining operation, cutting forces causes severe deformations in the proximity of the cutting edge, producing high stresses, strain, strain-rates and temperatures in the workpiece that ultimately affect the quality of the machined surface. In the present work, cutting forces generated in a vibro-impact and hot vibro-impact machining process of Ti-based alloy, using an in-house Ultrasonically Assisted Turning (UAT) setup, are studied. A three-dimensional, thermo-mechanically coupled, finite element model was developed to study the thermal and mechanical processes in the cutting zone for the various machining processes. Several advantages of ultrasonically assisted turning and hot ultrasonically assisted turning are demonstrated when compared to conventional turning.

The study of the curvature of the axis of the processed shaft when based in the centers using a steady rest

2021 ◽  
pp. 48-55
Author(s):  
A. V. Brylev ◽  
S. S. Mikheev
Keyword(s):  
Cutting Forces ◽  
Bending Moment ◽  
Elastic Displacement ◽  
Technological Equipment ◽  
Jigs And Fixtures ◽  
Additional Stability ◽  
Secondary Support ◽  
Overall Reliability

This paper presents the analysis and results of the study of a two-stage shaft fixed in dead centers and a rest device. Cutting forces act on the shaft, causing a bending moment. The analysis of the curvature of the axis of the workpiece, processed on a lathe when based in the centers, using a rest device, is carried out. The formula of elastic displacement of the workpiece axis at the place of the resulting cutting force is obtained. Diagrams of the stresses of the shaft axis displacements are constructed and a conclusion is made. The analysis showed that the greatest deflection is at the point of the cutting forces acting on the shaft. The quality of the part obtained after processing is characterized by accuracy. The parts mating in the product and, as a result, the overall reliability depends on how accurately the size and shape of the part will be maintained during processing. Parts with length of 10 to 12 times larger than the diameter are bent under the action of their own weight and cutting forces, as a result of which they get a barrel-like shape. It is possible to eliminate this by applying special devices for the machine. When processing long nonrigid workpieces, the tools, jigs and fixtures must evenly distribute the clamping force over the surface of the part. These conditions are well provided by technological equipment with pneumatic, hydraulic clamping devices, as well as with various collet clamps, split bushings, diaphragm or cartridges. When processing long non-rigid shafts, rest devices are used. The rest device plays the role of the main or secondary support when working with workpieces; it creates support for large, long parts during processing. It helps to avoid the risk of damage and deformation of the workpiece or the cutting elements of the machine, by giving the workpiece additional stability

A study on the vibrations in the external cylindrical grinding process of the alloy steels

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040150 ◽  
Author(s):  
Tuan-Linh Nguyen ◽  
Nhu-Tung Nguyen ◽  
Long Hoang
Keyword(s):  
Grinding Process ◽  
Cooling Mode ◽  
Workpiece Material ◽  
Cylindrical Grinding ◽  
Technology System ◽  
Machining Conditions ◽  
Material Hardness ◽  
Alloy Steels ◽  
External Cylindrical Grinding

The vibration during external cylindrical grinding is caused by many factors such as the rigidity of the technology system, machining modes, machining materials, cooling mode, etc. This paper employed a Taguchi method to design experiments and evaluate the influence of machining mode parameters and workpiece material hardness on the vibrations when machining some types of alloy steel in external cylindrical grinding process. The influence of machining conditions on the vibrations was investigated. Besides, the mathematical models of vibration amplitudes were also modeled. The achieved results can be used to control the vibrations through machining conditions to improve the surface quality of the product.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

Effect of minimum quantity lubrication and vortex tube cooling on laser-assisted micromilling of a difficult-to-cut steel

2020 ◽  
Vol 234 (11) ◽  
pp. 1422-1432 ◽  
Author(s):  
Pushparghya Deb Kuila ◽  
Shreyes Melkote
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Vortex Tube ◽  
Minimum Quantity Lubrication ◽  
Dimensional Accuracy ◽  
Burr Formation ◽  
Workpiece Material ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Cooling Methods

Laser-assisted micromilling is a promising micromachining process for difficult-to-cut materials. Laser-assisted micromilling uses a laser to thermally soften the workpiece in front of the cutting tool, thereby lowering the cutting forces, improving the dimensional accuracy, and reducing the tool wear. Thermal softening, however, causes the workpiece material to adhere to the tool and form a built-up edge. To mitigate this problem and to enhance micromachinability of the workpiece in laser-assisted micromilling, this article investigates the following lubrication and cooling methods: (1) minimum quantity lubrication and (2) vortex tube cooling. Experiments utilizing the two methods are carried out on a difficult-to-cut stainless steel (A286), and the surface morphology, tool condition, burr formation, groove dimensional accuracy, surface finish, and cutting forces are analyzed. Results show that the combination of laser-assisted micromilling and minimum quantity lubrication yields the least amount of tool wear, lower resultant force, better groove dimensional accuracy, and no built-up edge. While vortex tube cooling with laser-assisted micromilling produces smaller burrs compared to minimum quantity lubrication, it yields larger changes in groove dimensions and is characterized by built-up edge formation. Possible physical explanations for the experimental observations are given.

scholarly journals Investigation of the Subsurface Temperature Effects on Nanocutting Processes via Molecular Dynamics Simulations

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1220
Author(s):  
Michail Papanikolaou ◽  
Francisco Rodriguez Hernandez ◽  
Konstantinos Salonitis
Keyword(s):  
Molecular Dynamics ◽  
Molecular Dynamics Simulations ◽  
Process Parameters ◽  
Cutting Forces ◽  
Rake Angle ◽  
Von Mises Stress ◽  
Depth Of Cut ◽  
Subsurface Temperature ◽  
Workpiece Material ◽  
Dynamics Simulations

In this investigation, three-dimensional molecular dynamics simulations have been performed in order to investigate the effects of the workpiece subsurface temperature on various nanocutting process parameters including cutting forces, friction coefficient, as well as the distribution of temperature and equivalent Von Mises stress at the subsurface. The simulation domain consists of a tool with a negative rake angle made of diamond and a workpiece made of copper. The grinding speed was considered equal to 100 m/s, while the depth of cut was set to 2 nm. The obtained results suggest that the subsurface temperature significantly affects all of the aforementioned nanocutting process parameters. More specifically, it has been numerically validated that, for high subsurface temperature values, thermal softening becomes dominant and this results in the reduction of the cutting forces. Finally, the dependency of local properties of the workpiece material, such as thermal conductivity and residual stresses on the subsurface temperature has been captured using numerical simulations for the first time to the authors’ best knowledge.

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