Monitoring of chip breaking and surface roughness in computer numerical control turning by utilizing wavelet transform of dynamic cutting forces

2015 ◽  
Vol 231 (14) ◽  
pp. 2479-2494 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Kanyakarn Samanmit
Keyword(s):  
Surface Roughness ◽  
Wavelet Transform ◽  
Chip Formation ◽  
Cutting Forces ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Chip Breaking ◽  
Frequency Domains ◽  
Meyer Wavelet

The aim of this research is to monitor and classify the broken chip signals from the dynamic cutting forces, in order to predict the surface roughness during the computer numerical control turning process utilizing the Meyer wavelet transform to decompose the dynamic cutting forces. The dynamic cutting forces of the broken chips and the surface roughness can be decomposed into the different levels. The levels of decomposed cutting forces can aid to explain the broken chip formation and the surface roughness profile in both time and frequency domains. The experimentally obtained results showed that the surface roughness frequency occurs at the higher level of decomposed cutting forces, especially at the fifth level, although the cutting conditions are changed. However, the chip breaking frequency appears at the lower level, which depends on the cutting conditions and the chip length. The ratio of the fifth level of decomposed feed forces to that of main forces is proposed to predict the surface roughness during the in-process cutting. It is understood that the broken chip formation can be separated clearly and the surface roughness can be predicted well during the cutting, regardless of the cutting conditions.

A wavelet approach to predict surface roughness in ball-end milling

2015 ◽  
Vol 231 (14) ◽  
pp. 2468-2478 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Prae Thesniyom ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Wavelet Transform ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Detection System ◽  
Milling Process ◽  
Cutting Conditions ◽  
Ball End Milling ◽  
Dynamic Cutting Force

This research proposed an advance in the prediction of the in-process surface roughness during the ball-end milling process by utilizing the wavelet transform to monitor and decompose the dynamic cutting forces. The chatter detection system has been adopted from the previous research of the author to avoid the chatter first, and hence, the dynamic cutting force ratio is introduced to predict the in-process surface roughness during the normal cutting by taking the ratio of the decomposed dynamic cutting force in X axis to that in Z axis. The Daubechies wavelet transform is employed in this research to analyze the in-process surface roughness. The experimentally obtained results showed that the surface roughness frequency occurred at the same level of the decomposed dynamic cutting forces although the cutting conditions are changed. It is understood that the in-process surface roughness can be predicted effectively under various cutting conditions referring to the proposed monitoring system.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

scholarly journals PERFORMANCE OF COATED TUNGSTEN CARBIDE IN MILLING COMPOSITE BOARDS

Wood Research ◽  
2021 ◽  
Vol 66 (4) ◽  
pp. 606-620
Author(s):  
PUTRA PANGESTU KIDUNG TIRTAYASA ◽  
WAYAN DARMAWAN ◽  
DODI NANDIKA ◽  
IMAM WAHYUDI ◽  
LUMONGGA DUMASARI ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Tungsten Carbide ◽  
Chip Formation ◽  
Noise Level ◽  
Numerical Control ◽  
Wood Plastic Composite ◽  
Tungsten Carbides ◽  
Plastic Composite ◽  
Coated Carbide

The purpose of this research was to analyze the performance (wear resistance, surface roughness, chip formation, and noise level) of AlCrN, TiN, and TiAlN coated tungsten carbides in cutting composite boards. The composite boards of wood plastic composite, laminated veneer lumber, andorientedstrand board were cut by the coated tungsten carbide tools in a computer numerical control router. The results show that the differences in structure among the composite boards resulted in the difference in clearance wear, chip formation, surface roughness, and noise level phenomenon. The abrasive materials in wood plastic composite generated the highest clearance wear on the coated carbide tools tested. TiAlN coated carbide tool provided better wear resistance, smoother composite boards surfaces, and lower noise levels.

UGIMA NSU, UGIMA 303

Alloy Digest ◽  
1998 ◽  
Vol 47 (9) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Melting Point ◽  
Physical Properties ◽  
Tensile Properties ◽  
Heat Treating ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Cnc Lathe ◽  
Machine Work

Abstract UGIMA NSU and UGIMA 303 are the same grades designated differently for the European and North American markets, respectively. They are resulfurized grades with calcium added. Carefully controlled steelmaking results in a composition with oxides that have a low melting point and produce a lubricating effect during machining. Gains in the cutting conditions of 25 to 50% are typical on computer numerical control (CNC) lathe or classical machine work. This datasheet provides information on composition, physical properties, and tensile properties. It also includes information on corrosion resistance as well as forming, heat treating, machining, and joining. Filing Code: SS-709. Producer or source: Ugine-Savoie. Originally published March 1998, revised September 1998.

Prediction of Chip Flow Direction, Cutting Forces and Surface Roughness in Finish Turning

1998 ◽  
Vol 120 (1) ◽  
pp. 1-12 ◽  
Author(s):  
J. A. Arsecularatne ◽  
R. F. Fowle ◽  
P. Mathew
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Chip Flow ◽  
Edge Based ◽  
Tool Cutting ◽  
Good Agreement

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and cutting conditions. By defining an equivalent cutting edge based on the chip flow direction it is shown how cutting forces can be predicted under finishing conditions when the work material’s flow stress and thermal properties are known. A comparison between predicted and experimental results obtained for a range of tool geometries and cutting conditions shows good agreement. Surface roughness Ra values measured in the tests are compared with the theoretical values determined from the nose radius and feed.

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