Analyzing the effect of tool edge radius on cutting temperature in micro-milling process

2010 ◽  
Author(s):  
Y. C. Liang ◽  
K. Yang ◽  
K. N. Zheng ◽  
Q. S. Bai ◽  
W. Q. Chen ◽  
...  
Keyword(s):  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

scholarly journals Tool edge radius effect on cutting temperature in micro-end-milling process

2010 ◽  
Vol 52 (9-12) ◽  
pp. 905-912 ◽  
Author(s):  
Kai Yang ◽  
Ying-chun Liang ◽  
Kang-ning Zheng ◽  
Qing-shun Bai ◽  
Wan-qun Chen
Keyword(s):  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Micro End Milling ◽  
End Milling Process

scholarly journals Chatter Behavior in the Milling Process of Inconel 718: Effects of Tool Edge Radius

2018 ◽  
Vol 202 ◽  
pp. 02006
Author(s):  
C H Hoe ◽  
M M Reddy ◽  
V C C Lee ◽  
S Debnath
Keyword(s):  
Inconel 718 ◽  
Elevated Temperatures ◽  
Milling Process ◽  
Machining Process ◽  
Chatter Vibration ◽  
End Mill ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Variable Helix

Inconel 718 is widely used in various high end industries such as aerospace, nuclear plant, petrochemical plants etc. Inconel 718 is used for these applications due to unique mechanical properties such as high mechanical strength at elevated temperatures, high resistance to corrosion, and high strength to weight ratio. The unique properties of Inconel 718 made it difficult to be machined due to rapid work hardening and high cutting temperature. In addition, chatter vibration further increases the difficulty in machining of Inconel 718. In this paper, an experimental study on the effects of tool edge radius to the chatter behaviour was investigated. The dynamic responses of the milling process were recorded and analysed in both time domain and frequency domain. The results showed the variable helix and pitch end mill tool with larger tool edge radius able to mitigate chatter vibration at lower cutting speeds. Variable helix and pitch end mill with specific tool edge radius able to mitigate chatter vibration under the same cutting parameters. Experiments shows proper selection of tool edge radius improves the stability of end milling machining process.

Cutting Force Analysis in Micro Milling of Steel

2013 ◽  
Vol 774-776 ◽  
pp. 1017-1020 ◽  
Author(s):  
Bing Wu ◽  
Huai Zhong Li
Keyword(s):  
Cutting Force ◽  
Experimental Work ◽  
Micro Milling ◽  
Cnc Machine Tool ◽  
Force Analysis ◽  
Cnc Machine ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
End Mills

An analysis of cutting force performance in the micro milling on steel has been carried out based on an experimental work using micro flat end mills on a precision CNC machine tool. It has been found that cutting forces occurred at low feed per tooth are relatively high by assessing the averaged peak forces from the experiments. When feed per tooth is relatively close to tool edge radius, the forces were not growing in linearity with the increasing feedrate. This finding indicates the significance of ploughing phenomenon as an effect of tool edge radius in micro milling.

Finite Element Analysis of Micro-Cutting Aluminum 7050-T7451 with the Tool Edge Radius Considered

2010 ◽  
Vol 443 ◽  
pp. 663-668 ◽  
Author(s):  
Jun Zhou ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Cutting Temperature ◽  
Machining Process ◽  
Micro Machining ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

Effects of Tool Nose Corner Radius and Main Cutting-Edge Radius on Cutting Temperature in Micro-Milling Inconel 718 Process

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Likun Si ◽  
Steven Y. Liang
Keyword(s):  
Three Dimensional ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Cutter ◽  
Micro Scale ◽  
Cutting Edge Radius ◽  
Corner Radius ◽  
Edge Radius

Cutting temperature plays an important role in micro-scale cutting process because the dimension of the micro-milling cutter is relatively small and the wear of micro-milling cutter is sensitive to temperature. Considering the sidewall of a groove is formed by main cutting edge of the tool, and the bottom of a groove is formed by tool tip and the edge on the end of the tool. Therefore, effects of tool nose corner radius and main cutting edge radius on cutting temperature in micro-milling process cannot be ignored. However, few studies have been conducted on this issue. The effects of tool nose corner radius and main cutting edge radius on cutting temperature is investigated. A three-dimensional micro-milling Inconel718 model is established by using the software DEFORM3D. And the influence of tool nose corner radius and main cutting edge radius on the size and distribution of cutting temperature are studied by numerical simulation, which is verified by experiments. The work provide reference for the control of the size and distribution of the cutting temperature during micro-milling process.

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

2011 ◽  
Vol 223 ◽  
pp. 859-868 ◽  
Author(s):  
Shukri Afazov ◽  
Svetan Ratchev ◽  
Joel Segal
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Micro Milling ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Stability Lobes ◽  
Tool Edge ◽  
The Stability

This paper investigates the effects of the cutting tool edge radius on the cutting forces and stability lobes in micro-milling. The investigation is conducted based on recently developed models for prediction of micro-milling cutting forces and stability lobes. The developed models consider the nonlinearities of the micro-milling process, such as nonlinear cutting forces due to cutting velocity dependencies, edge radius effect and run-out presence. A number of finite element analyses (FEA) are performed to obtain the cutting forces in orthogonal cutting which are used for determining the micro-milling cutting forces. The chip morphology obtained for different tool edge radii using FEA is presented. It is observed that at large tool edge radii the influence of the ploughing effect become more significant factor on the chip morphology. The results related to micro-milling cutting forces and stability lobes show that by enlarging the tool edge radius the micro-milling cutting forces increase while the stability limits decrease.

Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

2016 ◽  
Vol 836-837 ◽  
pp. 374-380
Author(s):  
Teng Yi Shang ◽  
Li Jing Xie ◽  
Xiao Lei Chen ◽  
Yu Qin ◽  
Tie Fu
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Multiphase Model ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Insert ◽  
Multiphase Models ◽  
Hot Rolled ◽  
Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

Effects of tool edge radius on chip formation during the micromachining of pure iron

2020 ◽  
Vol 108 (7-8) ◽  
pp. 2121-2130
Author(s):  
Xiaoguang Guo ◽  
Yang Li ◽  
Linquan Cai ◽  
Jiang Guo ◽  
Renke Kang ◽  
...  
Keyword(s):  
Chip Formation ◽  
Pure Iron ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
On Chip

On the Steady-State Workpiece Flow Mechanism and Force Prediction Considering Piled-Up Effect and Dead Metal Zone Formation

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Cheng Hu ◽  
Weiwei Zhang ◽  
Kejia Zhuang ◽  
Jinming Zhou ◽  
Han Ding
Keyword(s):  
Stagnation Point ◽  
Shear Stresses ◽  
Flow Mechanism ◽  
Zone Formation ◽  
Force Prediction ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Dead Metal Zone ◽  
Tool Edge ◽  
Material Separation

Abstract The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three points characterizing the DMZ pattern and one inside considered as stagnation point. The normal and shear stresses as well as friction factors along the entire contact region are clarified based on slip-line theory. It is found that the friction coefficient varies symmetrically about the stagnation point inside DMZ and remains constant for the rest. Then, an analytical force prediction model is developed with Johnson–Cook constitutive model, involving calibrated functions of chip-tool contact length and cutting temperature. The assumed tribology condition and morphologies of material separation including DMZ are clearly observed and verified through various finite element (FE) simulations. Finally, comparisons of cutting forces from cutting experiments and predicted results are adopted for the validation of the predictive model.

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