Discrete Element Simulation of the Stress Wave in High Speed Milling

2017 ◽  
Author(s):  
Yifei Jiang ◽  
Jun Zhang ◽  
Yong He ◽  
Hongguang Liu ◽  
Afaque Rafique Memon ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Discrete Element ◽  
Rake Angle ◽  
Stress Waves ◽  
High Speed Milling ◽  
Element Simulation ◽  
Chip Size ◽  
Distribution Of Stress

As cutting tool penetrates into workpiece, stress waves is induced and propagates in the workpiece. This paper aims to propose a two-dimensional discrete element method to analyze the stress waves effects during high speed milling. The dependence of the stress waves propagation characteristics on rake angle and cutting speed was studied. The simulation results show that the energy distribution of stress waves is more concentrated near the tool tip as the rake angle or the cutting speed increases. In addition, the density of initial cracks in the workpiece near the cutting tool increases when the cutting speed is higher. The high speed milling experiments indicate that the chip size decreases as the cutting speed increases, which is just qualitatively consistent with the simulation.

Simulation of Fully Sintering Dental Zirconia Milling Process Based on Discrete Element Method

2013 ◽  
Vol 568 ◽  
pp. 49-54
Author(s):  
H.B. Wu ◽  
Q.P. Sun ◽  
Dun Wen Zuo
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Element Model ◽  
Discrete Element ◽  
Milling Process ◽  
Discrete Element Model ◽  
Surface Cracks ◽  
Coating Technology ◽  
Cutting Speeds

Discrete element model of fully sintering dental zirconia was constructed and calibrated. Based on the model, the dynamic process of low-speed milling of zirconia was simulated, and the effects of different cutting speeds, cutting widths and federates on the formation of surface cracks were also analyzed. Results show that residue cracks number and maximum depth increases significantly with increase of the cutting width, while the influence of cutting speed and federates is not distinct. That shows the possibility of high-speed machining on fully sintering dental zirconia with development of coating technology of cutting tool.

Optimization of Cutting/Tool Parameters for Dry High-Speed Spiral Bevel and Hypoid Gear Cutting with Cutting Simulation Experiment

2012 ◽  
Vol 472-475 ◽  
pp. 2088-2095 ◽  
Author(s):  
Gan Hua Liu ◽  
Hong Zhi Yan ◽  
Jun Jie Zhang
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Hypoid Gear ◽  
Gear Cutting ◽  
Relief Angle ◽  
Spiral Bevel

Tool life and the rationality of cutting parameter setting are evaluated directly by cutting force. In order to predict cutting force, and then to optimize the tooth cutting condition for dry high-speed spiral bevel and hypoid gear cutting, this study has established a 2D cutting FEM simulation platform by using DEFORM-2D based on the 2D orthogonal slot milling experiment. Through the platform, using the method of combining single-factor experiment and multi-factor orthogonal experiment, this study has explored the influence of cutting/tool parameters on cutting force in the dry high-speed cutting process of 20CrMnTi spiral bevel and hypoid gear (face hobbing dry cutting process). The results show that from high degree to low degree, the influence of each parameter on cutting force is as follows: feed > cutting speed > relief angle(P.A.side) >blade rake angle, and the influence of the first three parameters is significant, the influence of blade rake angle is not significant; the optimized condition for dry high-speed spiral bevel and hypoid gear cutting is suggested to be: the cutting speed is 300 m/mim, the feed is 0.06 mm/r, the blade rake angle is 14° and the relief angle(P.A.side) is 10°; the cutting edge can be honed moderately, but the hone radius is not bigger than 0.1 mm.

Simulation on Cutting Temperature during High-Speed Milling Aluminum Alloy 7055

2013 ◽  
Vol 328 ◽  
pp. 486-490 ◽  
Author(s):  
Liang Tan ◽  
Chang Feng Yao ◽  
Wei Zuo ◽  
Dao Xia Wu
Keyword(s):  
Aluminum Alloy ◽  
Theoretical Basis ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Milling Parameters

To optimize the parameters of high-speed milling of aluminum alloy 7055 and provide a theoretical basis for cutting temperature control, a finite element model of high-speed milling process of aluminum alloy 7055 was developed with AdvantEdge. Based on these models, the effect of milling parameters on cutting temperature is investigated by single factor experiments. And the temperature distribution of workpiece and cutting tool is predicted. The results show that the highest temperature occurs at close to the tool tip in the rack face, the temperature increases with an increase in cutting speed and feed per tooth, while other parameters have a less significant effect on cutting temperature.

Experimental Study on Specific Shear Energy in High-Speed Machining 7050-T7451

2013 ◽  
Vol 589-590 ◽  
pp. 8-12
Author(s):  
Guo Sheng Su ◽  
Zhan Qiang Liu
Keyword(s):  
Experimental Study ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Thermal Softening ◽  
High Speed Machining ◽  
Uncut Chip Thickness ◽  
Shear Energy

In this paper, the specific shear energy in high-speed machining 7050-T7451 from 100m/min to 3000m/min is measured and compared with the theoretical value evaluated by the method proposed by Pawade et al. (2009). The influences of cutting speed, rake angle of cutting tool, and uncut chip thickness are also investigated and discussed. Results show that the specific shear energy decreases with the increase of cutting speed, rake angle, and uncut chip thickness. The higher thermal softening makes the specific shear energy lower.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Effects of Cutting Parameters on Residual Stresses in High-Speed Milling of Ti-17

2013 ◽  
Vol 834-836 ◽  
pp. 861-865 ◽  
Author(s):  
Yong Shou Liang ◽  
Jun Xue Ren ◽  
Yuan Feng Luo ◽  
Ding Hua Zhang
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
High Speed ◽  
Experimental Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Single Factor ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Parameter Ranges

An experimental study was conducted to determine cutting parameters of high-speed milling of Ti-17 according to their effects on residual stresses. First, three groups of single factor experiments were carried out to reveal the effects of cutting parameters on residual stresses. Then sensitivity models were established to evaluate the influence degrees of cutting parameters on residual stresses. After that, three criteria were proposed to determine cutting parameters from experimental parameter ranges. In the experiments, the cutting parameter ranges are recommended as [371.8, 406.8] m/min, [0.363, 0.412] mm and [0, 0.018] mm/z for cutting speed, cutting depth and feed per tooth, respectively.

High-Speed Capturing of Stress Distribution of Workpiece under Ultrasonically Assisted Cutting Condition

2014 ◽  
Vol 1017 ◽  
pp. 747-752
Author(s):  
Hiromi Isobe ◽  
Keisuke Hara
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Light Emission ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Photoelastic Method ◽  
Intermittent Cutting ◽  
Ultrasonic Vibration Cutting

This paper reports the stress distribution inside the workpiece under ultrasonic vibration cutting (UVC) condition. Many researchers have reported the improvement of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVC condition. However general dynamometers have an insufficient frequency band to observe the processing phenomena caused by UVC. In this paper, stress distribution inside the workpiece during UVC was observed by combining the flash light emission synchronized with ultrasonically vibrating cutting tool and the photoelastic method. Instantaneous stress distribution during UVC condition was observed. Because UVC induced an intermittent cutting condition, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. It was found that instantaneous maximum cutting force during UVC condition was smaller than quasi-static cutting force during conventional cutting when the cutting speed was less than 500 mm/min.

Development of Tooling Cost Model for High Speed Hard Turning

2011 ◽  
Vol 418-420 ◽  
pp. 1482-1485 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz Al Hazza ◽  
Delvis Agusman ◽  
Agus Geter Edy Sutjipto
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cost Model ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Predictive Regression ◽  
Aisi 4340

The current work presents the development of cost model for tooling during high speed hard turning of AISI 4340 hardened steel using regression analysis. A set of experimental data using ceramic cutting tools, composed approximately of Al2O3 (70%) and TiC (30%) on AISI 4340 heat treated to a hardness of 60 HRC was obtained in the following design boundary: cutting speeds (175-325 m/min), feed rate (0.075-0.125 m/rev), negative rake angle (0 to -12) and depth of cut of (0.1-0.15) mm. The output data is used to develop a new model in predicting the tooling cost using in terms of cutting speed, feed rate, depth of cut and rake angle. Box Behnken Design was used in developing the model. Predictive regression model was found to be capable of good predictions the tooling cost within the boundary design.

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