TOOL STRESS PATTERN DEPENDING ON TOOL GEOMETRY

2010 ◽  
Vol 24 (15n16) ◽  
pp. 2792-2796
Author(s):  
YOUNG MOON LEE ◽  
WON SIK CHOI ◽  
JAE HWAN SON ◽  
SUN IL KIM ◽  
HEE CHUL JUNG
Keyword(s):  
Stress Distribution ◽  
Load Distribution ◽  
Metal Cutting ◽  
Tool Material ◽  
Stress Pattern ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Workpiece Material ◽  
Tool Stress ◽  
Material Tool

In metal cutting practices, for a given tool material, tool geometry is a very important element and must be carefully designed in relation to the workpiece material to be machined. Patterns of tool stress are varying with input cutting conditions; however, effects of tool geometry on tool stress are not clearly understood. The load distribution on tool face is affected by the tool geometry and this causes the change of the stress distribution on the tool.

On the Mechanism of Chip Breaking

1979 ◽  
Vol 101 (3) ◽  
pp. 241-249 ◽  
Author(s):  
S. Kaldor ◽  
A. Ber ◽  
E. Lenz
Keyword(s):  
Metal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Production Operation ◽  
Type Ii ◽  
Two Dimensional ◽  
Workpiece Material ◽  
Ductile Materials ◽  
Chip Breaking ◽  
Cutting Operation

During metal cutting while products are being manufactured, the access material is removed in the form of chips. These chips are obtained in various shapes which depend on cutting conditions, type of workpiece material machined, grade of the tool, geometry of cutting, etc. While brittle materials are being machined, the chips are segmental and disintegrating during the chip formation process. Consequently, these chips cause no difficulties. The problem exists when ductile materials are machined and one may observe the following chip forms: I—Long chips—(two dimensional and oblique type); II—Helical chips—(two dimensional and oblique type). These chips were classified by their influence on production operation. Based upon the natural crater developed during the cutting operation a chip breaker groove was introduced. These grooves are pressed into the insert during its manufacturing. It appears that the configuration of the groove has a crucial influence on the range of cutting conditions in which adequate breaking will occur. The presented paper deals with the different machinisms of chip breaking while machining with groove type chip breakers. Tests were carried out to establish the influence of the various parameters, taking part in the cutting operation, on the chip breaking process.

Residual Stress Prediction by Means of 3D FEM Simulation

2011 ◽  
Vol 223 ◽  
pp. 431-438 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Cristian Cappellini ◽  
Claudio Giardini
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Stress Measurement ◽  
Numerical Models ◽  
Orthogonal Cutting ◽  
Residual Stress Distribution ◽  
Tool Geometry ◽  
Distribution Analysis ◽  
3D Fem ◽  
Workpiece Material

In cutting field, residual stress distribution analysis on the workpiece is a very interesting topic. Indeed, the residual stress distribution affects fatigue life, corrosion resistance and other functional aspects of the workpiece. Recent studies showed that the development of residual stresses is influenced by the cutting parameters, tool geometry and workpiece material. For reducing the costs of experimental tests and residual stress measurement, analytical and numerical models have been developed. The aim of these models is the possibility of forecasting the residual stress distribution into the workpiece as a function of the selected process parameters. In this work the residual stress distributions obtained simulating cutting operations using a 3D FEM software and the corresponding simulation procedure are reported. In particular, orthogonal cutting operations of AISI 1045 and AISI 316L steels were performed. The FEM results were compared with the experimental residual stress distribution in order to validate the model effectiveness.

Modeling and Experimental Analysis of Acoustic Emission from Metal Cutting

1989 ◽  
Vol 111 (3) ◽  
pp. 229-237 ◽  
Author(s):  
R. Teti ◽  
D. Dornfeld
Keyword(s):  
Acoustic Emission ◽  
Experimental Analysis ◽  
Metal Cutting ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Simple Manner ◽  
Work Material ◽  
Theoretical Predictions

Testing parameters characterizing acoustic emission (AE) detected during metal cutting may be theoretically correlated, in a simple manner, to work material properites, cutting conditions, and tool geometry. Experimental results, obtained during turning by different researchers using different AE techniques, are presented and critically assessed with reference to their reciprocal agreement as well as their agreement with theoretical predictions. A review of current methods for AE analysis is also presented and the correlations between different AE parameters and energy and power of the detected signals are reported.

scholarly journals Testing Tool Material on Scratch Tester

2021 ◽  
Vol 9 (12) ◽  
pp. 1926-1930
Author(s):  
Saurav Salunke
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Tool Material ◽  
Workpiece Material ◽  
Research Article ◽  
Base Parameters ◽  
Tool Coating ◽  
Testing Tool ◽  
Cutting Operation

Abstract: In manufacturing industry cutting tools are considered as the backbone of the metal cutting operation. In metal cutting operation there is relative motion between the tool and the workpiece. As the tool material is harder than the workpiece material, there is deformation of the workpiece which acts as a base for the formation of chips. If we observe the process of metal cutting, we can easily find out that there is a considerable amount of heat generated during the machining operation. As there is a point of interface between the tool and the workpiece, there is absorption of generated heat into both the tool as well as work material. Due to the absorption of the heat there is distortion in the tool material. In this research article we have taken the base parameters as speed, load and stroke and the output parameter is taken as the load which breaks the coating of the tool. Keywords: tool coating, scratch tester, speed, stroke, coating.

scholarly journals An Experimental Investigation of Hot Machining with Induction to Improve Ti-5553 Machinability

2011 ◽  
Vol 62 ◽  
pp. 67-76 ◽  
Author(s):  
Maher Baili ◽  
Vincent Wagner ◽  
Gilles Dessein ◽  
Julien Sallaberry ◽  
Daniel Lallement
Keyword(s):  
Mechanical Properties ◽  
Cutting Forces ◽  
High Performance ◽  
Initial Temperature ◽  
Industrial Process ◽  
Tool Material ◽  
Cutting Conditions ◽  
Workpiece Material ◽  
Hot Machining ◽  
Productivity Rate

The manufacturing of aeronautic parts with high mechanical properties requires the use of high performance materials. That’s why; new materials are used for landing gears such as the titanium alloy Ti-5553. The machining of this material leads to high cutting forces and temperatures, and poor machinability which requires the use of low cutting conditions. In order to increase the productivity rate, one solution could be to raise the workpiece initial temperature. Assisted hot machining consists in heating the workpiece material before the material removal takes place, in order to weaken the material mechanical properties, and thus reducing at least the cutting forces. First, a bibliography review has been done in order to determine all heating instruments used and the thermal alleviation that exists on conventional materials. An induction assisted hot machining was chosen and a system capable to maintain a constant temperature into the workpiece during machining (turning) was designed. Trails permit to identify the variation of cutting forces according to the initial temperature of the workpiece, with fixed cutting conditions according to the TMP (Tool-Material-Pair) methodology at ambient temperature. Tool life and deterioration mode are identified notably. The results analysis shows a low reduction of specific cutting forces for a temperature area compatible with industrial process. The reduction is more important at elevated temperature. However, it has consequences on quality of the workpiece surface and tool wear.

scholarly journals Optimal Machining Parameters for Achieving the Desired Surface Roughness in Turning of Steel

2012 ◽  
Vol 9 (1) ◽  
pp. 37 ◽  
Author(s):  
LB Abhang ◽  
M Hameedullah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Engineering Sciences

 Due to the widespread use of highly automated machine tools in the metal cutting industry, manufacturing requires highly reliable models and methods for the prediction of output performance in the machining process. The prediction of optimal manufacturing conditions for good surface finish and dimensional accuracy plays a very important role in process planning. In the steel turning process the tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. In the present work, experimental investigations have been conducted to determine the effect of the tool geometry (effective tool nose radius) and metal cutting conditions (cutting speed, feed rate and depth of cut) on surface finish during the turning of EN-31 steel. First and second order mathematical models are developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using LINGO solver programs. LINGO is a mathematical modeling language which is used in linear and nonlinear optimization to formulate large problems concisely, solve them, and analyze the solution in engineering sciences, operation research etc. The LINGO solver program is global optimization software. It gives minimum values of surface roughness and their respective optimal conditions. 

A BEM/FEM Framework for Simulation of a Plastic Workpiece Deformed by an Elastic Tool

1995 ◽  
Vol 117 (3) ◽  
pp. 372-377 ◽  
Author(s):  
A. J. Beaudoin ◽  
P. R. Dawson ◽  
S. Mukherjee
Keyword(s):  
Tool Geometry ◽  
The Finite Element Method ◽  
Time Step ◽  
Workpiece Material ◽  
Contact Constraint ◽  
Tool Stresses ◽  
Tool Deflections ◽  
Material Tool ◽  
Solution Methodology ◽  
Element Method

A solution methodology is developed for the simulation of a plastic workpiece deformed by a compliant tool. The solution for elastic tool displacements is based on the Boundary Element Method (BEM); the viscoplastic response of the workpiece is computed using the Finite Element Method (FEM). At each time increment, tool deflections are recomputed from the elastic solution based on surface tractions developed in the previous converged solution for the viscoplastic response of the workpiece material. Tool stresses may be recovered at any point in the simulation using the BEM solution. The updated tool geometry and motion correspondingly modify the kinematic contact constraint applied in the viscoplastic solution over the subsequent time step. Application of this methodology is demonstrated for simulation of a plane strain forging operation.

Chip Flow and Scaling Laws in High Speed Metal Cutting

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Guy Sutter ◽  
Alain Molinari ◽  
Gautier List ◽  
Xuefeng Bi
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Scaling Laws ◽  
Scaling Law ◽  
Chip Morphology ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Workpiece Material ◽  
Machined Surface ◽  
Perfectly Plastic

Chip formation in machining plays an important role in the cutting process optimisation. Chip morphology often reflects the choice of cutting conditions, the tool wear and by consequences the integrity of the machined surface and tool life. In this study, photographs of the chip morphology during high speed machining of a middle hard steel (C20 similar to AISI 1020) are taken by using a ballistic setup. From these recordings, the evolution of the chip morphology is presented and analysed in terms of cutting conditions. A simplified modeling is then proposed by considering the workpiece material as elastic perfectly plastic. The existence of a scaling law governing the chip morphology in high speed machining is demonstrated. The cutting velocity is shown to have a weak effect at high speed machining as opposed to the well known strong influence of the velocity in the range of low cutting speeds.

scholarly journals Finite Element Modeling and Simulation of Machining of Titanium Alloy and H13 Tool Steel Using PCBN Tool

2013 ◽  
Vol 392 ◽  
pp. 36-40 ◽  
Author(s):  
S. Sulaiman ◽  
A. Roshan ◽  
S. Borazjani
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
High Temperature ◽  
Stress Distribution ◽  
Finite Element Modeling ◽  
Tool Steel ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Tool Material ◽  
Element Modeling

This paper deals with finite element modeling (FEM) and simulation of machining of titanium alloy and H-13 tool steel. Titanium alloys are very suitable for airframe manufacture and aircraft as H-13 uses forging dies and machined die casting. The machinability of both metals was evaluated by high temperature and tool wear. Finite element simulation was performed with ABAQUS explicit software to predict cutting temperature and stress distribution during metal cutting process. The purpose of this study was evaluation the performance of PCBN cutting tool material on machining of titanium alloy and H-13. It was found that PCBN tool can resistant well against high thermal shocks, high temperature and stress distribution when machining difficult to cut materials. The results can give a better understanding of cutting tool material for metal cutting process.

Improving the Economics of Machining PMMCs

1999 ◽  
Author(s):  
Mariam S. El-Gallab ◽  
Mateusz P. Sklad
Keyword(s):  
Mathematical Model ◽  
Surface Finish ◽  
Experimental Work ◽  
Feed Rate ◽  
Tool Material ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Optimum Cutting

Abstract It is the purpose of this paper to present a mathematical model for the prediction of surface finish during turning 20%SiC/Al particulate metal matrix composites (PMMCs). The surface finish relation to the cutting parameters (tool material, tool geometry, speed, feed rate and depth of cut) is further employed in a general form for tool life in order to arrive at optimum cutting parameters that would cost the least and yet meet the surface roughness requirements. A simple C++ program has been developed to find the optimum cutting conditions iteratively. The mathematical models quantify the results of an extensive experimental work on oblique turning of the SiC/Al PMMCs. The results of the experimental work reveal that increasing the feed rate up to 0.55 mm/rev. improves the tool wear rate. This is attributed to the reduced area of contact between the tool surface and the abrading SiC particles. Further increases in the feed rate results in tool failure by edge chipping. The optimum cutting conditions arrived at by the mathematical model yield 21–37% cost reduction when compared to the currently employed cutting parameters.

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