A new quick-stop device to study the chip formation mechanism in metal cutting: Computational and experimental investigation

2021 ◽  
pp. 095440622110342
Author(s):  
Mohamed Baccar Mhamdi ◽  
Wajdi Rajhi ◽  
Mohamed Boujelbene ◽  
Sahbi Ben Salem ◽  
Sonia Ezeddini ◽  
...  
Keyword(s):  
Chip Formation ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Hard Metal ◽  
Formation Mechanisms ◽  
Machining Parameters ◽  
Chip Formation Mechanism ◽  
Aisi D2 ◽  
Stop Test

Understanding the chip formation mechanisms during machining is an important factor to facilitate the choice of cutting tools and machining parameters. Despite the appearance of new sophisticated methods and advanced equipment, the technique so called quick-Stop Test (QST) remains efficient, less costly, and easier to apply in the investigation of chip formation in cutting process. In present paper a new Quick-Stop Device QSD is designed, numerically simulated, implemented, and tested. The reformed QST technique uses a QSD device which operates on the modified Charpy pendulum. Accordingly, design of new QSD is presented and deeply described, and 2D FE modeling of the new QST, including the application of the appropriate boundary conditions, has been carried out. Moreover, chip formation and morphology for different cutting conditions have been effectively simulated. Subsequently, quick stop cutting operations including metal cutting tests of high alloyed tool steel (AISI D2) using fabricated new QSD are performed. Preliminary results of quick-stop experiment from current investigation prove the effectiveness of the new designed QSD in matter of rigidity, safety, and absence of vibration, while providing a fast set up time and allowing extremely short workpiece-cutting tool separation time and guarantee the generation of chip with its root. The photomicrographs of chip root samples gathered from hard metal cutting experiments including various cutting speeds machining conditions, enables clear observation of segmented chip formation mechanisms, thereby, highly promising the new designed QSD for the purpose of investigation of the different cutting parameters influencing the chip formation and morphology.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

New Development in the Theory of the Metal-Cutting Process: Part II—The Theory of Chip Formation

1961 ◽  
Vol 83 (4) ◽  
pp. 557-568 ◽  
Author(s):  
P. Albrecht
Keyword(s):  
Shear Zone ◽  
Tool Life ◽  
Chip Formation ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Shear Plane ◽  
Cutting Process ◽  
Chip Formation Mechanism ◽  
Bending Stresses ◽  
Set Up

Introduction of the concept of ploughing into the metal-cutting process lead to the abandoning of the assumption of collinearity of the resultant force on tool face and on the shear plane. With this understanding the tool face force is found to produce a bending effect causing bending stresses in the shear zone. Study of the chip formation mechanism when varying cutting speed showed that increased bending action reduces the shear angle and vice versa. A set-up for the development of an analytical model of the chip formation process based on the combined effect of shear and bending stresses in the shear zone has been given. Application of the gained insight to the design of the cutting tool for maximum tool life by controlling of the chip-tool contact was suggested. Brief introduction to the study of cyclic events in chip formation and their relation to the tool life is presented.

scholarly journals Monitoring and neural network modeling of cutting temperature during turning hard steel

2018 ◽  
Vol 22 (6 Part A) ◽  
pp. 2605-2614
Author(s):  
Mirfad Taric ◽  
Pavel Kovac ◽  
Bogdan Nedic ◽  
Dragan Rodic ◽  
Dusan Jesic
Keyword(s):  
Neural Network ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Tool Material ◽  
Cutting Parameters ◽  
Neural Network Modeling ◽  
Machining Parameters ◽  
Average Temperature ◽  
Hard Steel

In this study, cutting tools average temperature was investigated by using thermal imaging camera of FLIR E50-type. The cubic boron nitride inserts with zero and negative rake angles were taken as cutting tools and round bar of EN 90MnCrV8 hardened steel was used as the workpiece. Since the life of the cutting tool material strongly depends upon cutting temperature, it is important to predict heat generation in the tool with intelligent techniques. This paper proposes a method for the identification of cutting parameters using neural network. The model for determining the cutting temperature of hard steel, was trained and tested by using the experimental data. The test results showed that the proposed neural network model can be used successfully for machinability data selection. The effect on the cutting temperature of machining parameters and their interactions in machining were analyzed in detail and presented in this study.

Study of Tapping Process of Ti6Al4V Using Finite Element (FE) Simulation

2020 ◽  
Author(s):  
Ali Daneji ◽  
Salman Pervaiz ◽  
Sathish Kannan
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
Process Conditions ◽  
Machining Performance ◽  
Workpiece Material ◽  
Significant Difference ◽  
Machining Operations

Abstract Finite element (FE) assisted numerical modeling approach is known as a popular approach to predict the machining performance of different machining operations. Tapping operation is a well-known manufacturing process that is used to cut threads efficiently. In the automotive and aerospace applications, precisely machined tapped holes are required in the small size deep holes. Tapping process creates thread in the hole and make it ready for fastening with other mating components. Tapping operation is considered as one of the most complex machining operations due to the presence of multi-flutes and multi-land involvement between the workpiece and cutter materials. The outcome of the tapping process results in the generation of threads and accepted as one of the most commonly employed in fastening methods for the joining of different machine components. Literature revealed that tapping process has been very rarely investigated using computational modeling approaches, as most of the available studies are experimental in nature. The experimental work for tapping operation can be very time and cost consuming because of the expensive fabrication of the cutting tools. It has also been observed experimentally that minor change in the threading profiles can generate significant difference in the cutting torque. A possible solution is to analyse the whole tapping operation using finite element (FE) assisted numerical simulation. Similarly, there will be limitation towards experiments if the workpiece material is expensive and difficult to cut. It is a common observation in metal cutting industry that most of the times cutting tap results in breakage when exposed to the higher magnitude of torque. The current study is aimed on the finite element based computational investigations on the tapping process using Ti6Al4V as a workpiece material. High hot hardness and low thermal conductivity of the Ti6Al4V also plays a significant role towards the poor machining performance of the threading tool. Ti6Al4V is most commonly employed in the engineering applications where high strength to weight ratio and ability of operate at higher temperatures is required. Ti6Al4V is mainly utilized in the automotive, aerospace, biomedical and petrochemical industries. It has been identified that tapping operation is very rarely studied machining operation in the metal cutting scientific community. Different tapping process conditions were investigated computationally using finite element (FE) approach and as a result cutting forces, torques and power consumed were observed. The study provides a useful understanding towards the tapping process mechanics with respect to different cutting parameters.

Multi-Constrained Analysis of Metal Cutting and its Application

2013 ◽  
Vol 589-590 ◽  
pp. 38-44
Author(s):  
Gang Liu ◽  
Ming Chen ◽  
Peng Nan Li ◽  
Qing Zhen Bi ◽  
Bao Cai Guo
Keyword(s):  
Thermal Conductivity ◽  
Stainless Steel ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Cutting Process ◽  
Optimization Strategy ◽  
First Time

The concept of multi-constrained analysis of the cutting process is presented for the first time in the paper. The paper adopts a method to solve an important problem which is how to judge the influence of constrains during the cutting process. The research results are applied for HSS drills for cutting stainless steel. On the basis of the multi-constrained analysis combined with methods of simulations and standard experiments, the optimum methods are provided for structure, coating and cutting parameters of cutting tools. For geometric structure of tools, optimization is to increase thickness of cutting and rake angle. Coating optimization strategy is choosing high temperature hardness and low thermal conductivity coating. Optimization of cutting parameter is to adjust feed fate, then select proper cutting speed. The conclusion of paper is helpful for the cutting optimization.

Reliability Analysis of Cutting Tools

1979 ◽  
Vol 101 (2) ◽  
pp. 185-190 ◽  
Author(s):  
K. Hitomi ◽  
N. Nakamura ◽  
S. Inoue
Keyword(s):  
Tool Wear ◽  
Reliability Analysis ◽  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Reliability Function ◽  
Statistical Distribution ◽  
Experimental Results ◽  
Machining Parameters ◽  
Cutting Experiments

This paper is concerned with the reliability analysis of tool life based on the tool-wear values obtained from metal cutting experiments. From experimental results, a statistical distribution of tool wear was decided, and the distribution of tool life and the reliability function of cutting tools were derived. Further, it was shown that the reliability of cutting tools at a certain time was easily calculated from machining parameters and tool-wear limits by the use of reliability function.

scholarly journals Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Chun Liu ◽  
Min Wan ◽  
Weihong Zhang ◽  
Yun Yang
Keyword(s):  
Formation Mechanism ◽  
Chip Formation ◽  
Inconel 718 ◽  
Cutting Tools ◽  
Iron Alloy ◽  
High Temperature Strength ◽  
Workpiece Material ◽  
Machined Surface ◽  
Wide Range ◽  
Chip Formation Mechanism

AbstractInconel 718, a nickel, chrome and iron alloy, has special advantages, such as high-temperature strength, thermal resistance and corrosion resistance, which facilitate wide usage in the aerospace industry, especially in the hot sections of gas turbine engines. However, machining this alloy is correlated closely with the material’s inherent properties such as excellent combination of strength, hardness and toughness, low thermal conductivity and the tendency to adhere to cutting tools. This nickel alloy also contains inclusions of hard abrasive carbide particles that lead to work-hardening of the workpiece material and thus abrasive wear of the cutting tool. That is, the machining of Inconel 718 is always influenced by high mechanical and thermal loads. This article reviews the chip formation mechanism of Inconel 718. One of the main characteristics in machining of Inconel 718 is that it will produce serrated or segmented chips in a wide range of cutting speeds and feeds. Existing studies show that the chip serration or segmentation by shear localization affects the machined surface integrity, and also contributes to the chip’s evacuation and the automation of machining operations. Thus, research conclusion indicates that the serrated or segmented chip phenomenon is desirable in reducing the level of cutting force, and detailed analysis of models and approaches to understand the chip formation mechanism of Inconel 718 is vital for machining this alloy effectively and efficiently. Therefore, this article presents some summaries on the models and approaches on the chip formation in machining of Inconel 718.

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.

High Current Extended DC Arc Plasma CVD for Mass Production of Diamond Film Coated Hard Metal Cutting Tools

2011 ◽  
Vol 211-212 ◽  
pp. 766-769 ◽  
Author(s):  
Fan Xiu Lu ◽  
Yong Ping Lv ◽  
Li Fu Hei ◽  
Wei Zhong Tang ◽  
Jian Hua Song
Keyword(s):  
Diamond Film ◽  
Mass Production ◽  
Metal Cutting ◽  
High Efficiency ◽  
Cutting Tools ◽  
Hard Metal ◽  
High Current ◽  
Plasma Cvd ◽  
Dry Cutting ◽  
Dc Arc

Diamond film coated hard metal cutting tools are indispensible for high efficiency machining of materials which are difficult to cut by ordinary tools, and are successfully used in the dry cutting of high silicon content Al-Si cast alloys, graphite, carbon reinforced composite (CRFC) and metal matrix composite (MMC) , ceramics, and many other materials. In the present presentation, a novel process of High Current Extended DC Arc (HCEDCA) plasma CVD for mass production of diamond film coated hard metal cutting tools is presented. Besides, a novel process for the pretreatment of the hard metal cutting tool substrate, which involves the idea of “surface engineering” consisting of boronizing and alkaline and acidic etching is also discussed, by which the adhesion of the diamond film coating to the hard metal substrate can be greatly enhanced. Highly adherent and uniform diamond film coatings are successfully obtained. Diamond film coated WC-6wt%Co indexable tool bits, drills, endmill samples have been produced and been shown having excellent cutting performance by field cutting tests in dry cutting of Al-12%Si cast alloy and Al-15% SiC MMC materials.

scholarly journals Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2467 ◽  
Author(s):  
Szymon Wojciechowski ◽  
Rafał Talar ◽  
Paweł Zawadzki ◽  
Stanisław Legutko ◽  
Radosław Maruda ◽  
...  
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Fold Increase ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Machined Surface ◽  
Cutting Path

The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.

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