Predictions of Cutting Force and Tool Wear in Gear Power Skiving

2021 ◽  
Author(s):  
Zongwei Ren ◽  
Zhenglong Fang ◽  
Takuhiro Arakane ◽  
Toru Kizaki ◽  
Yannan Feng ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Chip Thickness ◽  
Rake Angle ◽  
Parametric Modeling ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Rake Face ◽  
Power Skiving

Abstract Power skiving is a promising method that can enhance the efficiency of gear machining. The machining mechanism is complicated due to several factors, such as the continuous variation in the rake angle and undeformed chip thickness. The tool wear process is also difficult to be evaluated due to the constantly varying in cutting conditions. Hence, to make a comprehensive understanding of the cutting process, we proposed a parametric modeling process based on the kinematics of power skiving. In this model, the undeformed cutting chip was calculated in each pass and shows the consistency with deformed cutting chip in experiments. The effective rake angle and undeformed cutting chip thickness were defined, calculated, and displayed on undeformed cutting chip for a better understanding of the cutting process. The cutting force and tool crater wear were calculated by estimating the distribution of the stress and temperature on the rake face of the cutting tool. Multiple radial-feed experimental evaluations were conducted with the gears of construction vehicles. In the results, the predicted margin of the absolute error of the normal force on the rake face was under 5% in every pass. The wear distribution on the rake face is consistent with the superimposed tool-chip contact area. The results show high potential for the optimization of the cutting tool or cutting conditions in gear power skiving.

scholarly journals Cutting Force in Stone Machining by Diamond Disk

2010 ◽  
Vol 2010 ◽  
pp. 1-6 ◽  
Author(s):  
S. Turchetta
Keyword(s):  
Cutting Force ◽  
Process Parameters ◽  
Chip Thickness ◽  
Empirical Models ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Diamond Disk ◽  
Cutting Energy ◽  
Removal Process ◽  
Selection Of

Stone machining by diamond disk is a widespread process to manufacture standard products, such as tiles, slabs, and kerbs. Cutting force and energy may be used to monitor stone machining. Empirical models are required to guide the selection of cutting conditions. In this paper, the effects of cutting conditions on cutting force and cutting energy are related to the shape of the idealized chip thickness. The empirical models developed in this paper can be used to predict the variation of the cutting energy. Therefore these models can be used to guide the selection of cutting conditions. The chip generation and removal process has been quantified with the intention of assisting both the toolmaker and the stonemason in optimising the tool composition and cutting process parameters, respectively.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Development of the new-type indexable inserts with helical rake faces

1997 ◽  
Vol 211 (2) ◽  
pp. 159-164 ◽  
Author(s):  
N Fang ◽  
M Wang ◽  
C Nedeß
Keyword(s):  
Cutting Force ◽  
Rake Angle ◽  
Radial Force ◽  
Geometric Parameters ◽  
Cutting Conditions ◽  
Rake Face ◽  
Tool Insert ◽  
Tool Force ◽  
New Type ◽  
Indexable Insert

A kind of new-type indexable insert with a three-dimensionally shaped rake face, namely the helical rake face, is developed in this present work, contributing to the formation of short conical helical chips acceptable for modern automated and unattended machining systems. The geometric parameters of the helical rake face consist of the helical gradient, the helical length, the beginning rake angle at the tool nose and the end rake angle on the cutting edge. The influences of these parameters on the side-curling of the chip and on the chip breakability are investigated. Under the cutting conditions employed in this paper, the cutting force measuring results show that the cutting component of the resultant tool force and the radial force when using the tool insert with the helical rake face are less than those when using the type CNMG120408-ZF tool insert, a kind of commercially available insert widely used.

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.

Measurement and analysis of cutting forces on single point cutting tool in turning of MS bar with dry condition and rust-X cutting fluid

2016 ◽  
Vol 7 (3) ◽  
pp. 359-369 ◽  
Author(s):  
Pradeep Kumar Patil ◽  
A I Khandwawala
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Single Point ◽  
Rake Angle ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Experimental Setup ◽  
Rake Face ◽  
Content Type ◽  
Normal Forces

Purpose – The purpose of this paper is to measure the effect of rake angle on cutting forces on the rake face of single point cutting tool with two cutting conditions. The experimental setup has been developed to measure the cutting forces. The study aims to put forward the optimum cutting condition, which improves the product quality, surface finish, productivity and tool life. Design/methodology/approach – The load cell-based tool dynamometer has been developed to measure the cutting forces. The experiments have performed on the mild steel bar of hardness 60 BHN. The friction and the normal forces have measured in dry cutting condition and with rust-X cutting fluids. The cutting forces for these two cutting conditions have calculated with constant depth of cut, speed and feed with different rake angles in the range of degrees 6, 7, 8, 9, 10, 11, 12, 15 and 20. Findings – The experimental observations shows the variations of friction and normal forces with different cutting conditions and parameters. It shows the friction force on rake face increase and the normal force on the rake face decreases with increase the rake angle. Research limitations/implications – The observations has done only for mild steel of hardness 60 BHN. It can also be perform on different materials and for different cutting conditions. Practical implications – The experimental setup developed in this research can be used in the manufacturing industry. It can help to decide and maintain the optimum cutting conditions. Originality/value – The observations have been made on an experimental setup, which fulfills the actual working/cutting conditions as per the use in industries.

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.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

scholarly journals Enhancing Wear Resistance and Cutting Performance of a Long-Life Micro-Groove Tool in Turning AISI 201

Coatings ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1515
Author(s):  
Jinxing Wu ◽  
Lin He ◽  
Yanying Wu ◽  
Chaobiao Zhou ◽  
Zhongfei Zou ◽  
...  
Keyword(s):  
Temperature Field ◽  
Service Life ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Rake Face ◽  
Crater Wear ◽  
Wear Area

Tool-chip friction increases cutting temperature, aggravates tool wear, and shortens the service life of cutting tools. A micro-groove design of the rake face can improve the wear performance of the tool. In this study, we used the finite element simulation “Deform” to obtain the temperature field distribution of the tool rake face. The size of the micro-groove was determined by selecting a suitable temperature field combined with the characteristics of tool–chip flow in the cutting process, and the tool was prepared using powder metallurgy. The three-direction cutting forces and tool tip temperature were obtained by a cutting test. Compared with the original turning tool, the cutting force and cutting temperature of the micro-groove tool were reduced by more than 20%, the friction coefficient was reduced by more than 14%, the sliding energy was reduced and the shear energy was greatly decreased. According to the analysis of tool wear by SEM (scanning electron microscope) and EDS (energy dispersive X-ray spectroscopy), the crater wear, adhesive wear and oxidation wear of the micro-groove tool were lower than those of the original turning tool. In particular, the change in the crater wear area on the rake face of the original tool and the micro-groove tool was consistent with the cutting temperature and the wear width of the flank face. On the whole, the crater wear area and the change rate of the crater wear area of the micro-groove tool were smaller. Due to the proper microgroove structure of the rake face, the tool-chip contact area decreased, and the second rake angle of the tool became larger. Hence, the tool-chip friction, cutting forces, cutting energy consumption were reduced, tool wear was improved, and the service life of the micro-groove tool was five times longer than that of the original tool.

Turning of Inconel 718 by Cemented Carbides

2011 ◽  
Vol 496 ◽  
pp. 138-143 ◽  
Author(s):  
Ivan Mrkvica ◽  
Ryszard Konderla ◽  
Miroslav Faktor
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Cutting Parameters ◽  
Nickel Superalloy ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Cemented Carbides ◽  
Dry Turning ◽  
Cutting Inserts

This article deals with dry turning of nickel superalloy - Inconel 718. The different cemented carbides were applied for cutting process. These inserts were produced by Pramet Tools Ltd. company. This paper discusses durability of cutting inserts, the different intensity of tool wear at various cutting parameters. The most suitable cutting conditions are chosen in the scope of applied tools.

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