A Study of Cutting Forces for Milling Plain Carbon Steel Using Chamfered Main Cutting Edge Tools

1999 ◽  
Author(s):  
Chung-Shin Chang
Keyword(s):  
Cutting Forces ◽  
Plain Carbon Steel ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Material Force ◽  
Medium Carbon ◽  
Tool Geometries ◽  
Carbon Plate ◽  
Inclination Angles ◽  
Force Data

Abstract A new face milling model for tool geometries with a chamfered main cutting edge has been constructed. Theoretical values for cutting forces were calculated and compared to the experimental results with S45C medium carbon plate as the 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 Special tool holders were designed and manufactured to obtain various tool geometries, including chamfered main cutting edge, radial angle, axial angle and inclination angles. The tips were prepared to the required geometry using a tool grinder.

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 Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

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.

Electrical Current at Metal Cutting Process: A Literature Review

2015 ◽  
Vol 808 ◽  
pp. 40-47 ◽  
Author(s):  
Raluca Daicu ◽  
Gheorghe Oancea
Keyword(s):  
Literature Review ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Electrical Current ◽  
Cutting Edge ◽  
Cutting Process ◽  
Metallic Materials ◽  
Cutting Zone

Processing metallic materials by cutting using good electricity conductor cutting edges it appears an electrical current due mainly to the temperature in the cutting zone. Analyzing of the electrical current the information about the unfolding mode of the cutting process can be obtained. The cutting electrical current can be used in several applications: the estimation of the temperature in the cutting zone, the estimation of the cutting forces, the identification of the wear state of the cutting edge etc. The first researches were started in Russia and they were based on the utilization of the cutting electrical current to measure the temperature in the cutting zone. Afterwards, other applications were identified in the literature and the researches were extended in other countries like India, Japan, USA, Brazil, France, Bangladesh and Romania. This paper presents a review of the researches about the electrical current which appears at cutting process.

Process-Independent Force Characterization for Metal-Cutting Simulation

1997 ◽  
Vol 119 (1) ◽  
pp. 86-94 ◽  
Author(s):  
D. A. Stephenson ◽  
P. Bandyopadhyay
Keyword(s):  
Metal Cutting ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Baseline Data ◽  
Empirical Equations ◽  
Machining Processes ◽  
Workpiece Material ◽  
Bar Turning ◽  
Force Data

Obtaining accurate baseline force data is often the critical step in applying machining simulation codes. The accuracy of the baseline cutting data determines the accuracy of simulated results. Moreover, the testing effort required to generate suitable data for new materials determines whether simulation provides a cost or time advantage over trial-and-error testing. The efficiency with which baseline data can be collected is limited by the fact that simulation programs do not use standard force or pressure equations, so that multiple sets of tests must be performed to simulate different machining processes for the same tool-workpiece material combination. Furthermore, many force and pressure equations do not include rake angle effects, so that separate tests are also required for different cutter geometries. This paper describes a unified method for simulating cutting forces in different machining processes from a common set of baseline data. In this method, empirical equations for cutting pressures or forces as a function of the cutting speed, uncut chip thickness, and tool normal rake angle are fit to baseline data from end turning, bar turning, or fly milling tests. Forces in specific processes are then calculated from the empirical equations using geometric transformations. This approach is shown to accurately predict forces in end turning, bar turning, or fly milling tests on five common tool-work material combinations. As an example application, bar turning force data is used to simulate the torque and thrust force in a combined drilling and reaming process. Extrapolation errors and corrections for workpiece hardness variations are also discussed.

Diamond Coatings for Machining: Coating Thickness Effects

2009 ◽  
Author(s):  
Feng Qin ◽  
Y. Kevin Chou ◽  
Dustin Nolen ◽  
Raymond G. Thompson
Keyword(s):  
Residual Stresses ◽  
Coating Thickness ◽  
Cutting Forces ◽  
Failure Modes ◽  
Cutting Tools ◽  
Cutting Edge ◽  
The Other ◽  
Diamond Coatings ◽  
Coated Tools ◽  
Other Hand

Chemical vapor deposition (CVD)-grown diamond films have found applications as a hard coating for cutting tools. Even though the use of conventional diamond coatings seems to be accepted in the cutting tool industry, selections of proper coating thickness for different machining operations have not been often studied. Coating thickness affects the characteristics of diamond coated cutting tools in different perspectives that may mutually impact the tool performance in machining in a complex way. In this study, coating thickness effects on the deposition residual stresses, particularly around a cutting edge, and on coating failure modes were numerically investigated. On the other hand, coating thickness effects on tool surface smoothness and cutting edge radii were experimentally investigated. In addition, machining Al matrix composites using diamond coated tools with varied coating thicknesses was conducted to evaluate the effects on cutting forces, part surface finish and tool wear. The results are summarized as follows. (1) Increasing coating thickness will increase the residual stresses at the coating-substrate interface. (2) On the other hand, increasing coating thickness will generally increase the resistance of coating cracking and delamination. (3) Thicker coatings will result in larger edge radii; however, the extent of the effect on cutting forces also depends upon the machining condition. (4) For the thickness range tested, the life of diamond coated tools increases with the coating thickness because of delay of delaminations.

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