Assessment of Restricted Contact Cutting Tool in Dry Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Xianchen Ge ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Alpha Angle ◽  
Cutting Tools ◽  
Rake Face ◽  
Edge Radius ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper studies the performance of restricted cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using finite element simulations. The rake face of cemented carbide (WC/Co) cutting inserts is designed and the rake face length is shortened. The purpose is to examine the effect of shortened tools on machining performance and to compare it with regular cutting tools. The following restricted tool parameters are examined: length of rake face, alpha angle (the angle between the rake face and the supporting face), and edge radius. Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that restricted cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The length of rake face, the angle between the rake face and the supporting face, and edge radius all have influence on cutting force in their own ways. The effects of these three parameters on the tool temperature distribution are also investigated.

Assessment of the Performance of Microbumped Cutting Tool in Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Contact Length ◽  
Machining Performance ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

Assessment of Microgrooved Cutting Tool in Dry Machining of AISI 1045 Steel

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Jianfeng Ma ◽  
Nick H. Duong ◽  
Shing Chang ◽  
Yunsong Lian ◽  
Jianxin Deng ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Groove Depth ◽  
Groove Width ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper studies the performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using advantedge finite element simulation. Microgrooves are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microgroove textured tools on machining performance and to compare it with nontextured cutting tools. Specifically, the following groove parameters are examined: groove width, groove depth, and edge distance (the distance from cutting edge to the first groove). Their effects are assessed in terms of the main force, thrust force, and chip–tool contact length. It is found that microgrooved cutting tools generate lower cutting force and thrust force, and consequently lower the energy necessary for machining. The groove width, groove depth, and edge distance all have influence on cutting force in their own ways.

Investigation of the Effects of Microgrooved Cutting Tool in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Xingbang Chen ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Contact Length ◽  
High Speed Machining ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Cutting Inserts ◽  
1045 Steel

In this paper, numerical investigation of the effects of microgroove textured cutting tools in high speed machining of AISI 1045 is conducted using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of main cutting force, thrust force, and tool-chip contact length. It is found that microgrooved cutting tools generate lower cutting force and consequently lower the energy necessary for machining. This research provides insightful guidance for optimizing tool life and reducing energy consumption in high-speed machining of AISI 1045 steel.

CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Han Wu ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
High Speed Machining ◽  
Rake Face ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045 steel. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A coupled Eulerian-Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 steel with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of orthogonal high speed cutting of AISI 1045 using microgrooved cutting tools. It is also concluded that microgrooved cutting tools can not effectively reduce the cutting force in high speed machining, which is contrary to the conclusion obtained for low speed machining in previous research. However, microgrooves on the rake face have influence on the austenite percentage in the chip near the rake face. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation in high speed machining of AISI 1045 steel.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

Effect of longitudinally intermittent movement of cutting tool in drilling of AISI 1045 steel: A three-dimensional numerical simulation

2018 ◽  
Vol 233 (12) ◽  
pp. 4081-4090 ◽  
Author(s):  
Mohammad Lotfi ◽  
Saeid Amini
Keyword(s):  
Cutting Tool ◽  
Thrust Force ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Lower Temperature ◽  
Three Dimensional Finite Element ◽  
1045 Steel

Applying ultrasonic vibrations in machining process is an effective method to improve desired machinability factors. In this study, a three-dimensional finite element model is developed to evaluate effect of added vibratory movement of cutting tool on output parameters in conventional drilling of AISI 1045 steel. Heat generation on drill faces, strain, and damage of deformed chip in addition to thrust force are taken into account to be analyzed. Besides, a dynamometer and a vision measuring microscope are used to investigate generated thrust force and built-up edge during conventional and ultrasonic-assisted drilling. As a result, it is shown that vibratory movement of drill bit results in lower temperature to be generated on tool faces resulting in almost elimination of built-up edge. Moreover, higher damage value resulted by additional chip bending is observed when ultrasonic vibration is added to the operation.

Assessment of Microgrooved Cutting Tool in Dry Machining of AISI 1045 Steel: A Numerical Study

2013 ◽  
Author(s):  
J. Ma ◽  
Hung Duong ◽  
Yunsong Lian ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Numerical Study ◽  
Cutting Tools ◽  
Groove Depth ◽  
Groove Width ◽  
Machining Performance ◽  
Edge Distance ◽  
1045 Steel

This paper studies the performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI1045 steel) using Finite Element (FE) simulation to gain insights into how to improve performance of cutting tools. Microgrooves are designed on the rake face of tungsten carbide (WC) cutting inserts. The purpose is to test the effect of microgroove textured tools on machining performance and to compare it with non-textured cutting tools. Specifically, the following groove parameters are examined: groove width, groove depth, edge distance (the distance from cutting edge to the first groove). Their effects are assessed in terms of cutting force and thrust force. It is found that microgrooved cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The groove width, groove depth, and edge distance have big influence on the cutting force and thrust force. Consequently, this research provides insightful guidance for optimizing cutting tools.

scholarly journals Correction and accuracy improvement of non-parallel shear zone model

2018 ◽  
Vol 207 ◽  
pp. 02002
Author(s):  
Yaoke Wang ◽  
Meng Kou ◽  
Wei Ding ◽  
Huan Ma ◽  
Liangshan Xiong
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Shear Zone ◽  
Coordinate Transformation ◽  
Chip Thickness ◽  
Zone Model ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Experimental Values ◽  
1045 Steel

When applying the non-parallel shear zone model to predict the cutting process parameters of carbon steel workpiece, it is found that there is a big error between the prediction results and the experimental values. And also, the former approach to obtain the relevant cutting parameters of the non-parallel shear zone model by applying coordinate transformation to the parallel shear zone model has a theoretical error – it erroneously regards the determinant (|J|) of the Jacobian matrix (J) in the coordinate transformation as a constant. The shape of the shear zone obtained when |J| is not constant is drew and it is found that the two boundaries of the shear zone are two slightly curved surfaces rather than two inclined planes. Also, the error between predicted values and experimental values of cutting force and cutting thrust is slightly smaller than that of constant |J|. A corrected model where |J| is a variable is proposed. Since the specific values of inclination of the shear zone (α, β), the thickness coefficient of the shear zone (as) and the constants related to the material (f0, p) are not given in the former work, a method to obtain the above-mentioned five constants by solving multivariable constrained optimization problem based on experimental data was also proposed; based on the obtained experimental data of AISI 1045 steel workpiece cutting force, cutting thrust, chip thickness, the results of five above-mentioned model constants are obtained. It is found that, compared with prediction from uncorrected model, the cutting force and cutting thrust of AISI 1045 steel predicted by the corrected model with the obtained constants has a better agreement with the experimental values obtained by Ivester.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

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