scholarly journals Nonlinear Dynamics of Cutting Process considering Higher-Order Deformation of Composite Cutting Tool

2021 ◽  
Vol 2021 ◽  
pp. 1-23
Author(s):  
Donghui Yao ◽  
Yongsheng Ren ◽  
Yuhuan Zhang ◽  
Bole Ma
Keyword(s):  
Cutting Force ◽  
Nonlinear Dynamic ◽  
Cutting Tool ◽  
Primary Resonance ◽  
Higher Order ◽  
Forced Response ◽  
Cutting Process ◽  
Structural Damping ◽  
Superharmonic Resonance ◽  
Cutting System

In this paper, the nonlinear dynamic analysis of the cutting process of composite cutting tool is performed. The cutting tool is simplified to a nonplanar bending rotating shaft. The higher-order bending deformation, structural damping, and gyroscopic effect of cutting tool are considered. It is assumed that cutting tool is subjected to a regenerative two-dimensional cutting force containing the first and second harmonic components. Based on the Hamilton principle, the motion equation of nonlinear chatter of the cutting system is derived. The nonlinear ordinary differential equations in the generalized coordinates are obtained by Galerkin method. In order to analyze the nonlinear dynamic response of cutting process, the multiscale method is used to derive the analytical approximate solution of the forced response for the cutting system under periodic cutting forces. In the forced response analysis, four cases including primary resonance and superharmonic resonance, i.e., Ω ¯ = ω 1 , Ω ¯ = ω 2 , 2 Ω ¯ = ω 1 , and 2 Ω ¯ = ω 2 , are considered. The influences of ratio of length to diameter, structural damping, cutting force, and ply angle on primary resonance and superharmonic resonance are investigated. The results show that nonlinearity due to higher-order bending deformation significantly affects the dynamic behavior of the milling process and that the effective nonlinearity of the cutting system is of hard type. Multivalued resonance curves and jump phenomenon are presented. The influences of various factors, such as ratio of length to diameter, ply angle, structural damping, cutting force, and rotating speed, are thoroughly discussed.

scholarly journals Nonlinear Dynamic Analysis of the Cutting Process of a Nonextensible Composite Boring Bar

2020 ◽  
Vol 2020 ◽  
pp. 1-13
Author(s):  
Bole Ma ◽  
Yongsheng Ren
Keyword(s):  
Differential Equation ◽  
Dynamic Analysis ◽  
Cutting Force ◽  
Nonlinear Dynamic ◽  
Nonlinear Dynamic Analysis ◽  
Primary Resonance ◽  
Cutting Process ◽  
Cutting Depth ◽  
Resonance Curves ◽  
Cutting System

A nonlinear dynamic analysis of the cutting process of a nonextensible composite cutting bar is presented. The cutting bar is simplified as a cantilever with plane bending. The nonlinearity is mainly originated from the nonextensible assumption, and the material of cutting bar is assumed to be viscoelastic composite, which is described by the Kelvin–Voigt equation. The motion equation of nonlinear chatter of the cutting system is derived based on the Hamilton principle. The partial differential equation of motion is discretized using the Galerkin method to obtain a 1-dof nonlinear ordinary differential equation in a generalized coordinate system. The steady forced response of the cutting system under periodically varying cutting force is approximately solved by the multiscale method. Meanwhile, the effects of parameters such as the geometry of the cutting bar (including length and diameter), damping, the cutting coefficient, the cutting depth, the number of the cutting teeth, the amplitude of the cutting force, and the ply angle on nonlinear lobes and primary resonance curves during the cutting process are investigated using numerical calculations. The results demonstrate that the critical cutting depth is inversely proportional to the aspect ratio of the cutting bar and the cutting force coefficient. Meanwhile, the chatter stability in the milling process can be significantly enhanced by increasing the structural damping. The peak of the primary resonance curve is bent toward the right side. Due to the cubic nonlinearity in the cutting system, primary resonance curves show the characteristics of typical Duffing’s vibrator with hard spring, and jump and multivalue regions appear.

scholarly journals Forced Vibration in Cutting Process considering the Nonlinear Curvature and Inertia of a Rotating Composite Cutter Bar

2020 ◽  
Vol 2020 ◽  
pp. 1-19
Author(s):  
Yongsheng Ren ◽  
Donghui Yao
Keyword(s):  
Cutting Force ◽  
Forced Vibration ◽  
Multiple Scales ◽  
Damping Ratio ◽  
Three Dimensional ◽  
Forced Response ◽  
Cutting Process ◽  
Response Curves ◽  
Rotating Speed ◽  
Cutting System

Forced vibration of the cutting system with a three-dimensional composite cutter bar is investigated. The composite cutter bar is simplified as a rotating cantilever shaft which is subjected to a cutting force including regenerative delay effects and harmonic exciting items. The nonlinear curvature and inertia of the cutter bar are taken into account based on inextensible assumption. The effects of the moment of inertia, gyroscopic effect, and internal and external damping are also considered, but shear deformation is neglected. Equation of motion is derived based on Hamiltonʼs extended principle and discretized by the Galerkin method. The analytical solutions of the steady-state response of the cutting system are constructed by using the method of multiple scales. The response of the cutting system is studied for primary and superharmonic resonances. The effects of length-to-diameter ratio, damping ratio, cutting force coefficients, ply angle, rotating speed, and internal and external damping are investigated. The results show that nonlinear curvature and inertia imposed a significant effect on the dynamic behavior of the cutting process. The equivalent nonlinearity of the cutting system shows hard spring characteristics. Multiple solutions and jumping phenomenon of typical Duffing system are found in forced response curves.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

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.

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.

Non-Free Cutting and Its Degree of Freedom Confinement

1999 ◽  
Vol 121 (1) ◽  
pp. 150-153 ◽  
Author(s):  
H. Shi ◽  
X. Wang ◽  
Tao Lu
Keyword(s):  
General Theory ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Minimum Energy ◽  
Cutting Tools ◽  
Synthesis Method ◽  
Degree Of Freedom ◽  
Cutting Process ◽  
Good Agreement

Plunge-turning processes of round-edged cutters is analyzed and its cutting force modeled in the light of a general theory of non-free cutting developed by the authors. In this study the whole cutting tool is treated as a combination of a series of Elementary Cutting Tools (ECTs). Due to the non-linearity of chip-ejection interference among all the ECTs the total cutting force of the whole cutter, however, cannot be calculated by simply superposing the incremental cutting forces generated by all the ECTs. A Non-Linear Synthesis Method (NLSM) is therefore suggested for modeling this non-free cutting force. The main feature of the method is that the chip-ejection interference is under consideration and modeled on the basis of the Principle of Minimum Energy (PME). Good agreement between the predicted and measured main cutting forces is identified. Furthermore, a Coefficient of Non-Free Cutting (CNFC) is applied to quantitatively indicate the strength of chip-ejection interference among the ECTs and the degree of freedom confinement of the cutting process.

Actually Geometry of Milling Tool Involved in Cutting Process

2012 ◽  
Vol 723 ◽  
pp. 394-400 ◽  
Author(s):  
Zhen Yu Shi ◽  
Zhan Qiang Liu ◽  
Bing Wang
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Helix Angle ◽  
Cutting Process ◽  
Tool Geometry ◽  
Milling Tool ◽  
Sphere Radius ◽  
On Chip ◽  
Set Up ◽  
Milling Tools

The effect of cutting tool geometry has long been an issue in understanding mechanics of cutting process. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during cutting process. This paper presents the actually geometry of milling tool involved in cutting process based on mathematics analytical methods including matrix translation and rotation. Results show that according to the different helix angle and tool fluted, the geometry of cutting tool involved in cutting is different. For two or three-fluted mirco-milling tools, no mater helix angle is 30 or 45, the actually geometry involved in cutting is sphere. Different cutting tool corresponds to different sphere radius. Experiments were set up to validate the effect of cutting tool geometry on cutting forces. Results show that the smaller of the sphere radius of cutting tool, the lower of the cutting force; the larger of the sphere radius, the higher of the cutting force.

Determination of cutting force of roll-formed section in shaped dies-knife guillotine

2020 ◽  
pp. 373-376
Author(s):  
S.V. Povorov ◽  
D.V. Egorov ◽  
D.S. Volgin
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Sheet Blank

The change in cutting force in the cutting process of roll-formed section in shaped dies-knife guillotine is studied. It is established that to calculate the cutting force in shaped guillotine, one can use formulas to determine the cutting force of sheet blank on conventional straight knives guillotine.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

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