Study on Adhesion With Stress and Temperature in Drilling of Aluminum Alloy

2020 ◽  
Author(s):  
Takashi Matsumura ◽  
Satoshi Arakawa ◽  
Shoichi Tamura
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Flow Model ◽  
Cutting Temperature ◽  
Rake Face ◽  
Cutting Force Prediction ◽  
Chip Flow ◽  
Volume Method ◽  
Flat Tool ◽  
Cutting Speeds

Abstract Aluminum alloys have been widely used for automobile and aircraft parts. In cutting of aluminum alloy, adhesion sometimes occurs to deteriorate surface finish. The study discusses the adhesion characteristics in drilling of aluminum alloy (A7075) with a flat tool at a point angle of 180 degrees. The adhesion volumes on the rake face of the tool were measured in drillings of blind holes for the cutting speeds and the feed rates. Then, the stress and the temperature distributions were estimated in the cutting simulation. In the simulation, the cutting force is predicted in the chip flow model based on the minimum cutting energy. The cutting temperature is analyzed in Finite volume method using the result in the cutting force prediction. The adhesion volumes are associated with the stress and temperature on the rake face. The adhesion volume becomes large in the temperature ranged from 400 to 500 K. The adhesion volume increases with the stress up to 500 MPa.

scholarly journals Adaptive Cutting Force Prediction in Milling Processes

2010 ◽  
Vol 4 (3) ◽  
pp. 221-228 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Takahiro Shirakashi ◽  
Eiji Usui
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Model ◽  
Flow Direction ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Chip Flow

An adaptive force model is presented to predict the cutting force and the chip flow direction in milling. The chip flow model in the milling process is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The chip flow direction is determined to minimize the cutting energy. The cutting force is predicted using the determined chip flow model. The force model requires the orthogonal cutting data, which associate the orthogonal cutting models with the cutting parameters. Basically, the required data for simulation can be measured in the orthogonal cutting tests. However, it is difficult to perform the cutting tests with specialized setups in the machine shops. The paper presents the adaptive model to accumulate and update the orthogonal cutting data with referring the measured cutting forces in milling. The orthogonal cutting data are identified to minimize the error between the predicted and the measured cutting forces. Then, the cutting forces can be predicted well in many cutting operations using the identified orthogonal cutting data. The adaptive is effective not only in extending the database but also in improving the quality of the database for the accurate predictions.

A New Approach to Predict Machining Force and Temperature With Minimum Quantity Lubrication

2012 ◽  
Author(s):  
Xia Ji ◽  
Xueping Zhang ◽  
Steven Y. Liang
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Average Error ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Minimum Quantity ◽  
Cooling Effects ◽  
1045 Steel ◽  
Cutting Speeds

A new model to predict cutting force and temperature is developed by incorporating the lubrication and cooling effects generated from minimum quantity lubrication (MQL) machining. The boundary lubrication theory is utilized to estimate the friction behavior in prediction model. The model is capable of predicting cutting force and temperature in MQL machining directly from given cutting conditions, as well as material properties. Subsequently, the response of temperature distributions to chip formation and MQL is quantified on the basis of a moving heat source/loss model which iterates with the initial cutting force to achieve the final predictions. The predicted cutting temperature and cutting force are validated by the experimental data for AISI 9310 steel and AISI 1045 steel, respectively. Results show that under cutting speeds of 223–483 m/min, feed rates 0.10–0.18 mm/rev, depth of cut 1.0mm, the predicted cutting temperature at the tool-chip interface are generally lower than experimental measurements by 2% to 19%. And the model provides an average error of 11% for temperature prediction. With respect to cutting force prediction, the model provides a prediction error of 13% on the average in the cutting direction and 12% in the thrust direction within the experimental test condition range (cutting speeds of 45.75–137.25m/min, feeds 0.0508–0.1016 mm/rev, and depth of cut 0.508–1.016mm). In actual machining, the effects of possible tool wear causing higher temperature and force can contribute to deviations from model predictions involving only sharp tools.

Simulation Analysis of Aviation Aluminum Alloy Reaming Processes by Using PCD Reamer

2020 ◽  
Vol 866 ◽  
pp. 3-11
Author(s):  
J. Yin ◽  
W. Yang ◽  
Yong Guo Wang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Thrust Force ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
Spindle Speed ◽  
Analysis Software ◽  
Element Analysis ◽  
Speed Increase ◽  
Cutting Processes

Cutting force and cutting temperature are two important parameters in the cutting processes. In this paper, AdvantEdge finite element analysis software was used to simulate and analyze the reaming process of aviation aluminum alloy 7050 by using PCD reamer. The cutting simulation model was established to investigate the effect of spindle speed, feed per tooth on thrust force and cutting temperature. Simulation results showed that the cutting force increased with the increase of feed per tooth at different spindle speeds. And in the case of different feed per tooth, the cutting force decreased slightly as the spindle speed increase. Besides, from the cutting temperature distributed in the reamer, the cutting temperature near the tip of the tool in the reaming process was highest, the cutting temperature increased with the increase of both spindle speed and feed per tooth.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

The Coupling Thermal and Mechanical Analysis of Machining Aluminum Alloy Work-Piece Based on FEM

2013 ◽  
Vol 468 ◽  
pp. 20-23
Author(s):  
Mu Lan Wang ◽  
Jun Ming Hou ◽  
Bao Sheng Wang
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Digital Simulation ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Element Model ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Model

The Cutting force and cutting temperature are the important factors which can affect the quality and accuracy of the aluminum alloy work-pieces. Based on the theoretical analysis of the cutting force and cutting temperature, the three-dimensional Finite Element Model (FEM) with the overall tool is established. The corresponding results of the digital simulation were researched, and the cutting force and cutting temperature were analyzed. The cutting temperature and cutting force changes were compared by altering the axial depth of cut and the feed rate. Keywords: Oblique cutting model, Finite Element Method (FEM), Cutting temperature, Cutting force, Aluminum alloy work-piece

The Numerical Simulation of the Aluminum Alloy Processing

2011 ◽  
Vol 188 ◽  
pp. 590-595
Author(s):  
B.J. Xiao ◽  
Cheng Yong Wang ◽  
Ying Ning Hu ◽  
Yue Xian Song
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Element Model ◽  
Adaptive Meshing ◽  
Surface Residual Stress ◽  
Element Analysis ◽  
The Impact

A two-dimensional orthogonal thermal-mechanical finite element model by Deform2D finite element analysis software is established in the article. By the adaptive meshing technique, not only cutting process but also the effect on the process of aluminum alloy Al6061-T6 processing as friction coefficient changing is simulated. The simulation shows that the friction coefficient has significant effect on the cutting temperature and cutting force, and the effect is nonlinear. With the increasing of the friction coefficient, the cutting temperature and cutting force will both increase. The impact the friction coefficient has on the surface residual stress is much smaller than the impact on the cutting temperature and cutting force.

The Effects of a High-Pressure Coolant Jet on Machining

1994 ◽  
Vol 208 (1) ◽  
pp. 29-38 ◽  
Author(s):  
A R Machado ◽  
J Wallbank
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Cutting Temperature ◽  
Contact Length ◽  
Cutting Fluid ◽  
Rake Face ◽  
Chip Flow ◽  
High Pressure Coolant ◽  
Coolant System

A high-pressure coolant system was used to machine Ti6Al4V and Inconel 901. A 14.5 MPajet of cutting fluid was applied against the chip flow at the rake face of the tool and this works as an efficient chip-breaker. Conventional overhead flood cooling was also used to establish a base for comparison. Chip control, cutting force, cutting temperature, chip-tool contact length, surface integrity, tool lives and wear mechanisms were studied. The high-pressure coolant system used improved tool lives significantly when machining the titanium alloy but it proved to be detrimental to tool lives when machining the nickel alloy.

Study on Cutting Forces and Surface Finish During End Milling of Titanium Alloy

2014 ◽  
Author(s):  
Krishnaraj Vijayan ◽  
Samsudeen Sadham ◽  
Saikumar Sangeetha ◽  
Kuppan Palaniyandi ◽  
Redouane Zitoune
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Cutting Speeds

This paper investigates numerical and experimental study of end milling of titanium alloy Ti–6% Al–4% V using carbide insert based cutting tool. The experiments were carried out under dry cutting conditions. The cutting speeds selected for the experiments are 20,30,40,50 mmin–1. The feed rates used in the experiment were 0.02, 0.04, 0.06 and 0.08 mmrev–1, while depth of cut is kept constant at 1.0 mm. For conducting the experiments single insert based cutting tool is based. For a range of cutting speeds and feeds measurements of cutting force, surface roughness and cutting temperature have been recorded. From the experimental study it can be seen that cutting speed has the significant effect on temperature when compared to feed/tooth. Further it is also found that cutting speed of 30 m min−1 and feed rate of 0.02 mm rev−1 could be used for machining Ti alloy. Moreover the experimental and numerical cutting force values are compared.

Preliminary Study: The Effect of Tool Engagement and Cutting Speed on Cutting Temperature during Contour Tool Path Strategy

2015 ◽  
Vol 1115 ◽  
pp. 86-89
Author(s):  
Roshaliza Hamidon ◽  
Erry Y.T. Adesta ◽  
Muhammad Riza
Keyword(s):  
Cutting Force ◽  
Tool Path ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Engagement Angle ◽  
Preliminary Study ◽  
Cutting Speeds

In pocketing operation for mold and die, the variation of tool engagement angle causes variation in the cutting force and also cutting temperature. The objective of this study is to investigate the effect of tool engagement on cutting temperature when using the contour in tool path strategy for different cutting speeds. Cutting speeds of 150, 200 and 250m/min, feedrate from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were applied for the cutting process. The result shows that by increasing cutting speed, the cutting temperature would rise. Varying the tool engagement also varied the cutting temperature. This can be seen clearly when the tool makes a 90oturn and along the corner region. Along the corner, the engagement angle varies accordingly with the radial depth of cut.

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