Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

Research on Wear Mechanisms while Turning Titanium Alloy TC4

2010 ◽  
Vol 97-101 ◽  
pp. 1845-1848
Author(s):  
Dong Liu ◽  
Wu Yi Chen ◽  
Hong Hai Xu ◽  
Xue Ke Luo
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
High Chemical ◽  
Adhesion Wear ◽  
Wear Tool ◽  
High Chemical Activity

Titanium alloys are widely used in aerospace industry due to their excellent mechanical properties. Because of their low thermal conductivity, high chemical activity, large friction coefficient and so on, such problems occur during the cutting process as high cutting temperature, large specific cutting force and serious tool wear, leading to low machining efficiency. The cutting force, forms of tool wear; wear mechanics were experimentally studied and analyzed while machining titanium alloy TC4 using carbide tools YS8 and YG8. The experimental results indicated that the tool wear of YG8 influenced cutting force not very remarkable when flank wear smaller than 0.25mm. But when the flank wear was bigger than 0.25mm, the cutting force increased rapidly with the flank wear increased. And the tool wear influenced the cutting force dramatically. The forms of tool wear during machining TC4 using carbide tool were adhesion wear, tool chipping and. The desquamation and chipping of tool caused by adhesion wear were the main reason of the tool failure.

Studies on Tool Wear Monitoring Based on Cutting Force

2011 ◽  
Vol 697-698 ◽  
pp. 268-272 ◽  
Author(s):  
Mao Hua Xiao ◽  
Ning He ◽  
Lei Li
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flexible Manufacturing ◽  
Manufacturing System ◽  
Force Model ◽  
Cutting Force Model ◽  
Monitoring Tool ◽  
Cutting Test ◽  
On Line ◽  
Wear Monitoring

On-line tool wear sensing was an important subject in the Flexible Manufacturing System. Mathematic method is applied in this paper to analyze the correlation between cutting force and tool wear, and a cutting force model was established based on the tool wear. The predicted value of cutting force was calculated through the cutting test. Predicted value by comparison with the experimental data verifies the accuracy of the cutting force model. On this basis, a new method for monitoring tool wear based on measuring cutting force was proposed.

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

scholarly journals Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

2020 ◽  
Vol 285 ◽  
pp. 116809 ◽  
Author(s):  
Bastien Toubhans ◽  
Guillaume Fromentin ◽  
Fabien Viprey ◽  
Habib Karaouni ◽  
Théo Dorlin
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Force Model ◽  
Cutting Force Model

scholarly journals Identification of eccentricity for disc milling cutter of indexable two sided inserts

2021 ◽  
Vol 13 (8) ◽  
pp. 168781402110414
Author(s):  
Gensheng Li ◽  
Chao Xian ◽  
Hongmin Xin
Keyword(s):  
Tool Wear ◽  
Machine Tool ◽  
Cutting Force ◽  
Cutting Forces ◽  
Theoretical Method ◽  
Force Model ◽  
Cutting Force Model ◽  
Milling Cutter ◽  
Machining Quality ◽  
Operation Status

Tool eccentricity has a significant impact on machining quality, accuracy, and operation status of machine tool. It is difficult to accurately identify tool eccentricity. In this paper, the mathematical models of instantaneous undeformed cutting thickness and cutting force considering tool eccentricity are determined by theoretical method. Based on the model, the identification method for eccentricity parameters is proposed, and the eccentricity parameters of disc milling cutter is identified. According to the identified parameters, the cutting force is verified. The results show that most of the values of measured cutting forces are greater than the predicted ones considering tool eccentricity. In the future, it is necessary to establish a new cutting force model considering both tool eccentricity and tool wear.

Predictive Modeling of Flank Wear in Turning Under Flood Cooling

2006 ◽  
Vol 129 (3) ◽  
pp. 513-519 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Metal Cutting ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machining Process ◽  
Analytical Models ◽  
Dynamic Strain ◽  
Process Conditions ◽  
Force Analysis

The objective of this paper is to present physical and quantitative models for the rate of tool flank wear in turning under flood cooling conditions. The resulting models can serve as a basis to predict tool life and to plan for optimal machining process parameters. Analytical models including cutting force analysis, cutting temperature prediction, and tool wear mechanics are presented in order to achieve a thermo-mechanical understanding of the tool wear process. The cutting force analysis leverages upon Oxley’s model with modifications for lubricating and cooling effect of overhead fluid application. The cutting temperature was obtained by considering workpiece shear deformation, friction, and heat loss along with a moving or stationary heat source in the tool. The tool wear mechanics incorporate the considerations of abrasive, adhesion, and diffusion mechanisms as governed by contact stresses and temperatures. A model of built-up edge formation due to dynamic strain aging has been included to quantify its effects on the wear mechanisms. A set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the material-dependent coefficients in the models. Experimental cutting data were also used to validate the predictive models by comparing cutting forces, cutting temperatures, and tool lives under various process conditions. The results showed that the predicted tool lives were close to the experimental data when the built-up edge formation model appropriately captured this phenomenon in metal cutting.

Physics-Based Predictive Cutting Force Model in Ultrasonic-Vibration-Assisted Grinding for Titanium Drilling

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Na Qin ◽  
Z. J. Pei ◽  
C. Treadwell ◽  
D. M. Guo
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Removal Rate ◽  
Cutting Temperature ◽  
Brittle Materials ◽  
Force Model ◽  
Rotary Ultrasonic Machining ◽  
Cutting Force Model ◽  
Input Variables ◽  
Ultrasonic Vibration Assisted Grinding

Ultrasonic-vibration-assisted grinding (UVAG) or rotary ultrasonic machining has been investigated both experimentally and theoretically. Effects of input variables on output variables in UVAG of brittle materials and titanium (Ti) have been studied experimentally. Models to predict the material removal rate in UVAG of brittle materials have been developed. However, there is no report on models of cutting force in UVAG. This paper presents a physics-based predictive model of cutting force in the UVAG of Ti. Using the model developed, influences of input variables on cutting force are predicted. These predicted influences are compared with those determined experimentally. This model can serve as a useful template and foundation for development of cutting force models in UVAG of other materials (such as ceramics and stainless steels) and models to predict torque, cutting temperature, tool wear, and surface roughness in UVAG.

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