Experimental Investigations for Characterization and Analysis of Rake Face of the WC-Co Inserts Using Taguchi Method

2010 ◽  
Author(s):  
C. L. V. R. S. V. Prasad ◽  
S. V. Ramana ◽  
S. Srikiran ◽  
K. Ramji
Keyword(s):  
Taguchi Method ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Flow Patterns ◽  
System Level ◽  
Experimental Investigations ◽  
Work Piece ◽  
Rake Face ◽  
Experimental Conditions ◽  
Chip Flow

In order to improve the performance of the cutting tool, it is required to model the metal cutting process at the system level. To predict and enhance the cutting tool performance the primary requirement of the system is the efficiency of the model explaining the interactions at the tool chip interface. The predominating parameters which influence the development of the system are work piece material and machining variables or sometimes both. Further the development of low cost methodology to study the chip tool interactions with minimum amount of testing is of more importance. Major part of the work is emphasized on the investigation and characterization of various zones on the rake face of tungsten carbide inserts. Tests have been carried out by machining AISI 1040 steel using WC inserts with variable dry conditions examining the chip flow phenomenon on the rake face of considerable number of samples. Taguchi method is adopted for the design of experimental conditions. Results have shown an acceptable chip flow patterns and authors were able to quantify the wear zones on the rake face. The rake face is then characterized to represent all the possible cases of chip flow patterns, crater wear and chipping of the cutting edge. Side and end cutting edges are taken as datum lines for locating the wear zones. The quantification and locations of the wear zones might help the researchers and tool makers to concentrate more on the defined areas instead of the rake face in total.

Stress Distribution in a Wedge for Boundary Conditions Approximating to the Rake-Face Loads on a Metal Cutting Tool

1973 ◽  
Vol 15 (3) ◽  
pp. 200-209 ◽  
Author(s):  
P. F. Thomason
Keyword(s):  
Stress Distribution ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Contact Length ◽  
Rake Face ◽  
Line Field ◽  
Tangential Stresses ◽  
Detailed Assessment ◽  
Metal Cutting Tool ◽  
Infinite Wedge

An analysis of published experimental and theoretical slip-line field results for the metal cutting process suggests that, when the tool and workpiece are of high elastic modulus, a reasonable first approximation to the rake-face loading will consist of uniformly distributed normal and tangential stresses over the contact length. An indication of the form of the stress distribution at the tip of a cutting tool is therefore obtained from an isothermal–elastic solution for a two-dimensional infinite wedge, loaded antisymmetrically by uniform normal and tangential stresses adjacent to the apex. Only a preliminary assessment of the results is made, in relation to cutting tool wear and fracture problems, since a more detailed assessment will await a complete thermoelastic solution to the problem.

Topographic Wear Monitoring of the Interface Tool/Workpiece in Milling AISI H13 Steel

2014 ◽  
Vol 966-967 ◽  
pp. 152-167 ◽  
Author(s):  
Alejandro Pereira ◽  
Javier Martínez ◽  
Maria Teresa Prado ◽  
José A. Pérez ◽  
Thomas Mathia
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Experimental Investigations ◽  
Work Piece ◽  
H13 Steel ◽  
Hard Milling ◽  
Aisi H13 Steel ◽  
Ticn Coating ◽  
Aisi H13 ◽  
Wear Monitoring

The wear of TiCN coating carbide cutting tools (Sandvik® Grade 1010 and 4220) in different hard-milling machining conditions was monitored, analyzed, and discussed for AISI H13 steel. This material is commonly used in the forge industry in order to optimize the manufacturing process according to a qualimetry/cost compromise criterion. AISI H13 steel generally is used in modern production for high wear-resistant dies and molds. One of the most basic and primary geometric shapes in the manufacture of molds and die cavities is the geometry known as "inclined plane." Experimental investigations were carried out on a "mold model" design with the aim of analyzing and optimizing the principal manufacturing conditions. The tests are dependent on manufacturing factors, particularly their impactin a complex tribological process. Five clearly defined different surfaces of the hardened AISI H13 steel model mold, with appropriate geometries were studied; i) vertical downward; ii) curved downward; iii) horizontal; iv) curved upward; and v) vertical upward.The analysis of cutting tool wear during this process was based on computerized measurements of visually observable wear and power consumption. Morphological investigations of the surface topography for the cutting tool, as well as of the work-piece surfaces, were systematically carried out. Moreover, the interactions with simultaneously measured energy consumption during the process are also explicated in the present study and therefore tentative methods to optimize hard-milling machining are offered.

Basic Mechanics of the Metal-Cutting Process

1944 ◽  
Vol 11 (3) ◽  
pp. A168-A175 ◽  
Author(s):  
M. Eugene Merchant
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Work Piece ◽  
Machining Operations ◽  
Work Done ◽  
Metal Work

Abstract The author presents a mathematical analysis of the geometry and mechanics of the metal-cutting process, covering two common types of geometry which occur in cutting. This analysis offers a key for the study of engineering problems in the field of metal cutting in terms of such fundamental quantities as strain, rate of shear, friction between chip and tool, shear strength of the metal, work done in shearing the metal and in overcoming friction, etc. The two cases covered are, in essence, that of a straight-edged cutting tool moving relative to the work-piece in a direction perpendicular to its cutting edge, termed “orthogonal cutting,” and that of a similar cutting tool so set that the cutting edge is oblique to the direction of relative motion of tool and work, termed “oblique cutting.” Equations are developed which permit the calculation of such quantities as those just enumerated from readily observable values. The theoretical findings are particularly applicable and significant in the case of present-day high-speed machining operations with sintered-carbide tools.

Cutting Force and Friction Modelling in High Speed End-Milling

2015 ◽  
Author(s):  
Sunday J. Ojolo ◽  
Olumuwiya Agunsoye ◽  
Oluwole Adesina ◽  
Gbeminiyi M. Sobamowo
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece

Temperature field in metal cutting process is one of the most important phenomena in machining process. Temperature rise in machining directly or indirectly determines other cutting parameters such as tool life, tool wear, thermal deformation, surface quality and mechanics of chip formation. The variation in temperature of a cutting tool in end milling is more complicated than any other machining operation especially in high speed machining. It is therefore very important to investigate the temperature distribution on the cutting tool–work piece interface in end milling operation. The determination of the temperature field is carried out by the analysis of heat transfer in metal cutting zone. Most studies previously carried out on the temperature distribution model analysis were based on analytical model and with the used of conventional machining that is continuous cutting in nature. The limitations discovered in the models and validated experiments include the oversimplified assumptions which affect the accuracy of the models. In metal cutting process, thermo-mechanical coupling is required and to carry out any temperature field determination successfully, there is need to address the issue of various forces acting during cutting and the frictional effect on the tool-work piece interface. Most previous studies on the temperature field either neglected the effect of friction or assumed it to be constant. The friction model at the tool-work interface and tool-chip interface in metal cutting play a vital role in influencing the modelling process and the accuracy of predicted cutting forces, stress, and temperature distribution. In this work, mechanistic model was adopted to establish the cutting forces and also a new coefficient of friction was also established. This can be used to simulate the cutting process in order to enhance the machining quality especially surface finish and monitor the wear of tool.

Finite Element Modeling of Burr Formation in Orthogonal Metal Cutting

2008 ◽  
Vol 53-54 ◽  
pp. 71-76 ◽  
Author(s):  
Wen Jun Deng ◽  
C. Li ◽  
Wei Xia ◽  
X.Z. Wei
Keyword(s):  
Finite Element ◽  
Steady State ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Element Model ◽  
Burr Formation ◽  
Cutting Condition ◽  
Simulation Procedure ◽  
Chip Flow ◽  
Orthogonal Metal Cutting

A coupled thermo-mechanical model of plane-strain orthogonal metal cutting including burr formation is presented using the commercial finite element code. A simulation procedure based on Normalized Cockroft-Latham damage criterion is proposed for the purpose of better understanding the burr formation mechanism and obtaining a quantitative analysis of burrs at exit. The cutting process is simulated from the transient initial chip formation state to the steady-state of cutting, and then to tool exit transient chip flow, by incrementally advancing the cutting tool. The effects of cutting condition on the non-steady-state chip flow while tool exit can be investigated using the developed finite element model.

Machining Characteristics of Leaded Steel

1960 ◽  
Vol 82 (2) ◽  
pp. 347-359 ◽  
Author(s):  
Fenton L. Bagley ◽  
Roy Mennell
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Work Piece ◽  
Two Dimensional ◽  
Life Data ◽  
Wide Range ◽  
Machining Characteristics ◽  
Lead Addition ◽  
Cutting Speeds

The effects of lead addition in alloy steel upon the metal-cutting process were explored over a wide range of conditions. In particular, a range of cutting speeds (from 50 to 800 fpm) and workpiece hardness (from 230 to 450 Bhn) were investigated on one work-piece material (4340) using principally a carbide (C-6) cutting tool. Orthogonal (two-dimensional) data was taken to describe the metal-cutting process, and tool-life data were obtained by running a typical production tool to failure at the various cutting conditions. Several mechanisms to explain experimental results, including lead acting as a lubricant, are discussed.

Adhesion in metal cutting: a study in the SEM

1978 ◽  
Vol 36 (1) ◽  
pp. 586-587
Author(s):  
V.M. Silva ◽  
E.D. Doyle
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Edge ◽  
Rake Face ◽  
Additional Insight ◽  
Forming Process ◽  
Chip Surface ◽  
Intimate Contact ◽  
Dynamic Events ◽  
Insight Into

In a recent review of friction in metal cutting Bailey (1) claimed that it was now almost universally accepted that there was seizure or sticking contact between the chip and the tool in the immediate vicinity of the cutting edge, as indicated schematically in Fig. 1. This conclusion is rationalised on the basis that the sliding contact involves the continual generation of an uncontaminated chip surface at the cutting edge and that there is intimate contact between the chip and tool because of the high normal pressures on the rake face. However, recent work by Home et al. (2) using a transparent sapphire tool, revealed that the chip moves up the rake face of the cutting tool with no apparent seizure contact in the region of the cutting edge. In order to provide additional insight into this problem we have video-recorded the dynamic events in machining by carrying out the chip forming process within the evacuated chamber of the scanning electron microscope.

Comparison Vibration Amplitude for Magnetic Damping in Turning of Stainless Steel AISI 304

2013 ◽  
Vol 394 ◽  
pp. 251-255 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Ummu Atiqah Khairiyah Bt. Mohamad ◽  
Muammer D. Arif ◽  
Asan Gani Bin Abdul Muthalif
Keyword(s):  
Stainless Steel ◽  
Metal Cutting ◽  
Permanent Magnets ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Work Piece ◽  
Aisi 304 ◽  
Cutting Stability ◽  
Steel Aisi ◽  
Stainless Steel Aisi

This paper presents the improvement in chatter vibration damping using different types and arrangements of magnets, as well as comparison with normal cutting conditions in turning of stainless steel AISI 304. Chatter is defined as the self-excited violent relative motion between the cutting tool and work-piece. It is the common vibration problem that limits the productivity of machining processes, since it leads to shortened tool life, poor surface finish, breakage and premature damage of cutting tool, as well as mechanical deterioration. The occurrence of chatter during metal cutting process also causes instability of the machine tool system. Though there has been a large number of works on identifying the causes of chatter and its behavior, there is still no consensus among researchers on this very vital issue of machining. Previously, the incidence of chatter was thought to be due to forced vibration, BUE formation, cutting speed, and cracking during chip formation. Different ways to overcome this problem have been investigated, such as using piezoelectric inertia actuators, feed-forward neural network controllers, and work-piece preheating methods. In this research, permanent magnets with different size, strength, and composition are mounted around the cutting tool. A vibration sensor (accelerometer) is placed at the bottom of the tool to record the suppression of chatter amplitude in turning operation. It is shown that magnetic force can modify the frequency response function of the cutting tool resulting in improved cutting stability in turning operations. Chatter can then be effectively suppressed due to increased cutting stability.

The Numerical Investigation of Stress Distribution on the Rake Face for Grooved Cutting Tool Inserts

2011 ◽  
Vol 223 ◽  
pp. 304-313
Author(s):  
E. Kwiatkowska ◽  
Piotr Niesłony ◽  
W. Grzesik
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Process ◽  
Rake Face ◽  
Normal Stresses ◽  
Von Mises ◽  
Von Mises Stresses ◽  
Chip Breakage

The development of an accurate model for the shear and normal stresses on the rake face is very important for modeling of the metal cutting mechanics. It is known that the stresses vary over the contact surfaces of the tool and change substantially with their configurations. On the other hand, the recent attempts were generally addressed to orthogonal cutting process and tools with flat rake faces. At present, grooved tools with complex rake faces are commonly applied in the industry. In this study a plane strain finite element (FEM) program AdvantEdge was used to simulate the cutting process with some disposable grooved cutting tools. Both the reduced von Mises stresses and their components in x and y directions were considered and visualized for appropriate chip formation stages. In particular, the distribution of the contact stresses was revealed when chip breakage occurs. The simulated results were correlated with the geometry of the chip breaker and process parameters.

Development of Cutting Tool With Built-In Thin Film Thermocouples for Measuring High Temperature Fields in Metal Cutting Processes

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Jun Shinozuka ◽  
Ali Basti ◽  
Toshiyuki Obikawa
Keyword(s):  
Thin Film ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Plain Carbon Steel ◽  
Temperature Fields ◽  
Rake Face ◽  
Different Types ◽  
Thin Film Thermocouples ◽  
Cutting Processes

In order to measure temperature fields on tool face during cutting, a cutting tool with built-in thin film thermocouples (TFTs) has been devised. The TFTs composed of a nickel and nichrome thin films were fabricated on the rake face near the cutting edge of a sintered alumina tool insert using a physical vapor deposition and photolithography technique. An empirical formula that shows Seebeck coefficient of a TFT depends on electrical resistance of the TFT circuit was established. Three different types of tools in number and size of TFTs were developed and temperature fields on the rake face in cutting of a plain carbon steel S45C were measured. The results of the cutting thermometry experiment reveal that the devised tool with built-in three TFTs can measure temperature fields on the tool face and can sense slight change in cutting situation.

Sign in / Sign up

Export Citation Format

Share Document