scholarly journals Numerical Simulation of Rock Cutting with a Diamond Sawblade Based on LS-DYNA

2019 ◽  
Vol 2019 ◽  
pp. 1-15
Author(s):  
Zhiwen Wang ◽  
Qingliang Zeng ◽  
Zhenguo Lu ◽  
Lirong Wan ◽  
Xin Zhang
Keyword(s):  
Numerical Simulation ◽  
Hard Rock ◽  
Great Influence ◽  
Cutting Parameters ◽  
Rock Cutting ◽  
Feed Speed ◽  
Specific Cutting Energy ◽  
Cutting Depth ◽  
Cutting Energy ◽  
Diamond Sawblade

Aiming at the complex nonlinear dynamic problem of cutting hard rock with diamond sawblades, the process of hard rock cutting with a diamond sawblade was studied based on ANSYS/LS-DYNA. A numerical simulation model of a diamond sawblade cutting hard rock with different rotation speeds, feed speeds, and cutting depths was established to study the effects of the cutting parameters on the cutting force and specific cutting energy consumption and on the damage to the rock. The numerical simulation results demonstrated that the feed speed and cutting depth of the diamond saw are quadratically correlated with the cutting force, but the rotation speed is negatively linearly correlated. The damage region of the rock is positively correlated with the feed speed and cutting depth of the diamond sawblade and has a negative correlation with the rotation velocity. The cutting parameters have a great influence on specific cutting energy consumption. Analysis of the relationship among the cutting parameters and the specific cutting energy with multivariate linear fitting indicated that the cutting speed and cutting depth have a great influence on the cutting energy.

scholarly journals Numerical Investigation of the Rock Cutting Performance of a Circular Sawblade

2020 ◽  
Vol 2020 ◽  
pp. 1-18
Author(s):  
Zhiwen Wang ◽  
Qingliang Zeng ◽  
Zhenguo Lu ◽  
Zhihai Liu ◽  
Xu Li
Keyword(s):  
Cutting Force ◽  
Great Influence ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Rock Cutting ◽  
Rock Breaking ◽  
Feed Speed ◽  
Specific Cutting Energy ◽  
Cutting Depth ◽  
Cutting Energy

The rock cutting process with a circular sawblade and the rock breaking mechanism of rock are studied with a numerical simulation method in this paper. The influence of cutting parameters of the circular sawblade on cutting force, rock damage, and specific cutting energy in the process of circular sawblade cutting rock is researched. The cutting force increases with the feed speed and an increase in cutting depth and decline in rotation speed. Cutting rock with double circular sawblades can reduce cutting force. However, the specific cutting energy declines with the increase in cutting depth and the decline in the distance between the double circular sawblades. Cutting parameters have a great influence on the damage range of rock. The research results can be applied to rock processing with a circular sawblade.

scholarly journals Numerical Simulation of the Influence of the Distance between the Diamond Sawblade and Free Surface on Cutting Performance

2021 ◽  
Vol 2021 ◽  
pp. 1-13
Author(s):  
Qingliang Zeng ◽  
Zhiwen Wang ◽  
Zhenguo Lu ◽  
Lirong Wan ◽  
Xin Zhang
Keyword(s):  
Numerical Simulation ◽  
Free Surface ◽  
Cutting Force ◽  
Tangential Force ◽  
Surface Damage ◽  
Cutting Performance ◽  
Feed Speed ◽  
Rock Damage ◽  
Cutting Depth ◽  
Diamond Sawblade

The diamond sawblade has been widely used in the field of rock mining and processing. This article, through the establishment of a numerical simulation model of diamond sawblade cutting rock, studies the influence of the distance between the diamond sawblade and free surface on cutting performance. In the process of diamond sawblade cutting rock, with the increase of the distance from the sawblade to the free surface, the average cutting force, normal force, and tangential force of the sawblade increase at first and then stabilize, and the axial force gradually decreases and tends to be stable. In the process of cutting rock with fixed depth, cutting force and rock damage are positively related to feed speed and cutting depth of the diamond sawblade. Through the statistical analysis of rock damage by image recognition program statistics, it is concluded that the feed speed and cutting depth of the sawblade have a significant impact on the rock damage value. When the distance increases to 12 mm, there is a relatively complete rock plate between the sawblade and free surface. The rock free surface damage disappears when distance reaches 16 mm. The research results provide a theoretical basis for the sawblade processing rock plate.

scholarly journals Effects of Focus Geometry on the Hard Rock-Cutting Performance of an Abrasive Waterjet

2020 ◽  
Vol 2020 ◽  
pp. 1-13 ◽  
Author(s):  
Yohan Cha ◽  
Tae-Min Oh ◽  
Gye-Chun Cho
Keyword(s):  
Momentum Transfer ◽  
Hard Rock ◽  
Empirical Relationship ◽  
Abrasive Particle ◽  
Rock Cutting ◽  
Maximum Energy ◽  
Cutting Performance ◽  
Granitic Rocks ◽  
Abrasive Waterjet ◽  
Cutting Depth

Abrasive waterjets are being increasingly used in civil engineering for rock and concrete cutting, particularly for the demolition or repair of old structures. The energy of an abrasive waterjet is primarily provided by the accelerated abrasive. The momentum transfer during mixing and acceleration determines the abrasive velocity, which affects the cutting performance. Meanwhile, the geometry of the focus at which mixing occurs influences the momentum transfer efficiency. In this study, the effects of the focus geometry on the optimum abrasive flow rate (AFR) and momentum transfer characteristics in hard rock cutting were investigated. Experiments were conducted using granite specimens to test the AFR under different focus geometry conditions such as diameter and length. The results show that the focus geometry significantly affects the maximum cutting depth and optimum AFR. The maximum cutting energy was analyzed based on the cutting efficiency of a single abrasive particle. In addition, the momentum transfer parameter (MTP) was evaluated from the empirical relationship between the maximum energy and the cutting depth for granitic rocks. Accordingly, a model for estimating the MTP based on the AFR was developed. It is expected that the results of this study can be employed for the optimization of waterjet rock cutting.

scholarly journals Modeling and analysis of specific cutting energy of whirling milling process based on cutting parameters

Procedia CIRP ◽  
2019 ◽  
Vol 80 ◽  
pp. 56-61 ◽  
Author(s):  
Lexiang Wang ◽  
Yan He ◽  
Yufeng Li ◽  
Yulin Wang ◽  
Chao Liu ◽  
...  
Keyword(s):  
Cutting Parameters ◽  
Milling Process ◽  
Specific Cutting Energy ◽  
Modeling And Analysis ◽  
Cutting Energy

Optimization of Cutting Parameters Based on Specific Cutting Energy Consumption for Aluminum 6010 by Using the Analysis of Variance (ANOVA)

2016 ◽  
Vol 842 ◽  
pp. 14-18
Author(s):  
Sri Raharno ◽  
Yatna Yuwana Martawirya ◽  
Heng Rath Visith ◽  
Jeffry Aditya Cipta Wijaya
Keyword(s):  
Energy Consumption ◽  
Analysis Of Variance ◽  
Minimum Energy ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Manufacturing Industries ◽  
Depth Of Cut ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Minimum Energy Consumption

Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

scholarly journals Experimental Investigation on Machinability of Polypropylene Reinforced with Miscanthus Fibers and Biochar

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1181
Author(s):  
Dinh Son Tran ◽  
Victor Songmene ◽  
Anh Dung Ngo ◽  
Jules Kouam ◽  
Arturo Rodriguez-Uribe ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Ultrafine Particles ◽  
Thrust Force ◽  
Experimental Studies ◽  
Cutting Parameters ◽  
Drill Bit ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy

The machinability of composite materials depends on reinforcements, matrix properties, cutting parameters, and on the cutting tool used (material, coating, and geometry). For new composites, experimental studies must be performed in order to understand their machinability, and thereby help manufacturers establishing appropriate cutting data. In this study, investigations are conducted to analyze the effects of cutting parameters and drill bit diameter on the thrust force, surface roughness, specific cutting energy, and dust emission during dry drilling of a new hybrid biocomposite consisting of polypropylene reinforced with miscanthus fibers and biochar. A full factorial design was used for the experimental design. It was found that the feed rate, the spindle speed, and the drill bit diameter have significant effects on the thrust force, the surface roughness, and the specific cutting energy. The effects of the machining parameters and the drill bit diameter on ultrafine particles emitted were not statistically significant, while the feed rate and drill bit diameter had significant effects on fine particle emission.

Influence of Cutting Parameters on Characteristics of Serrated Chip when High-Efficiency Cutting Ti6Al4V

2011 ◽  
Vol 175 ◽  
pp. 278-283
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
De Qiang Zhang ◽  
Ning Liu ◽  
Yi Hang Fan
Keyword(s):  
High Frequency ◽  
High Efficiency ◽  
Great Influence ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Cutting Depth ◽  
Serrated Chip ◽  
Geometric Characteristics ◽  
Serrated Chips

During the process of high-efficiency cutting Ti6Al4V the material presents serrated chips. Periodic high-frequency serrated ship will cause fluctuations in the cutting force, which then affect the tool wear and surface integrity of workpiece and so on. On the basis of experiment of turning Ti6Al4V, the frequency and the geometric characteristics of serrated chip has been analyzed through observing the microstructure of chip using optical microscope and SEM. The results show that cutting speed and feed rate have great influence on the frequency and the geometric characteristics of serrated chip. Involving low-speed, large feed and large cutting depth can reduce the generated frequency of serrated chip.

Research on the Size Effect of Specific Cutting Energy Based on Numerical Simulation of Single Grit Scratching

2018 ◽  
Vol 140 (7) ◽  
Author(s):  
Tao Zhang ◽  
Feng Jiang ◽  
Lan Yan ◽  
Xipeng Xu
Keyword(s):  
Numerical Simulation ◽  
Size Effect ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Simulation Results ◽  
The Relationship ◽  
Single Grit Scratch

A method of research on the size effect of the specific cutting energy based on the numerical simulation has been proposed. The theoretical model of the research on size effect of specific cutting energy using single grit scratching simulation has been presented. A series of single grit scratch simulations with different scratching depths have been carried out to acquire different material removal rates. Then, the specific cutting energy has been calculated based on the power consumed and the material removal rate. The relationship between the specific cutting energy and the material removal rate has been given which agrees well with that presented by Malkin. The simulation results have been analyzed further to explain the size effect of specific cutting energy.

scholarly journals Numerical Simulation of Fragment Separation during Rock Cutting Using a 3D Dynamic Finite Element Analysis Code

2017 ◽  
Vol 2017 ◽  
pp. 1-17 ◽  
Author(s):  
Zhenguo Lu ◽  
Lirong Wan ◽  
Qingliang Zeng ◽  
Xin Zhang ◽  
Kuidong Gao
Keyword(s):  
Numerical Simulation ◽  
Compressive Strength ◽  
Linear Relationship ◽  
Specific Energy ◽  
Cutting Forces ◽  
Rock Cutting ◽  
Cutting Depth ◽  
Conical Pick ◽  
Simulation Results ◽  
Base Rock

To predict fragment separation during rock cutting, previous studies on rock cutting interactions using simulation approaches, experimental tests, and theoretical methods were considered in detail. This study used the numerical code LS-DYNA (3D) to numerically simulate fragment separation. In the simulations, a damage material model and erosion criteria were used for the base rock, and the conical pick was designated a rigid material. The conical pick moved at varying linear speeds to cut the fixed base rock. For a given linear speed of the conical pick, numerical studies were performed for various cutting depths and mechanical properties of rock. The numerical simulation results demonstrated that the cutting forces and sizes of the separated fragments increased significantly with increasing cutting depth, compressive strength, and elastic modulus of the base rock. A strong linear relationship was observed between the mean peak cutting forces obtained from the numerical, theoretical, and experimental studies with correlation coefficients of 0.698, 0.8111, 0.868, and 0.768. The simulation results also showed an exponential relationship between the specific energy and cutting depth and a linear relationship between the specific energy and compressive strength. Overall, LS-DYNA (3D) is effective and reliable for predicting the cutting performance of a conical pick.

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