scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

Quality Inspection and Analysis of Workpiece Surface in A3 Steel Machining

2011 ◽  
Vol 55-57 ◽  
pp. 451-455 ◽  
Author(s):  
Qi Yong Zeng ◽  
Kai Wu ◽  
Xiao Feng Zheng ◽  
Ming Zhu
Keyword(s):  
Data Acquisition ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Cutting Temperature ◽  
Quality Characteristics ◽  
Measuring System ◽  
Time Data ◽  
Data Acquisition Card ◽  
High Speed Data Acquisition

Quality characteristics of steel workpiece and their inspection methods are introduced, and the influencing factors of surface quality are analyzed by quality tools. A set of inspection scheme for cutting temperature and cutting force on-line monitoring is worked out. Thin film thermocouple technology was introduced to measure the dynamic temperature which affects the surface quality characteristics of steel workpieces. A system for measuring cutting temperature and cutting force has been developed. A high speed data acquisition card ADlink PCI-9118HG is used to acquire the temperature and force signals. Simple and friendly human-machine interface was programmed with the application of VC++ technology and Tchart controllor to achieve real-time data acquisition, display and analysis of cutting temperature and cutting force. It was concluded from the experiment that the data acquisition and measuring system is easy and flexible to use.

The Effect of Tool Edge Preparation of Indexable Carbide Insert

2012 ◽  
Vol 499 ◽  
pp. 342-347
Author(s):  
Xi Yue Zou ◽  
J.F. Sun ◽  
W.Y. Chen ◽  
J.X. Xie
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Cutting Temperature ◽  
Feed Force ◽  
Cutting Force Measurement ◽  
Tool Edge ◽  
Strain Gauge Dynamometer ◽  
Temperature Force ◽  
Edge Preparation ◽  
Carbide Insert

The paper focused on the effect of tool edge preparation of indexable carbide insert on cutting temperature, force and tool wear. The initial wear experiments were carried out to measure flank wear and two criteria to evaluate the effect of tool edge preparation were proposed. The cutting temperature measurement utilized tool-work thermocouple and revealed that the cutting temperature of honed insert was lower. The cutting force measurement with a strain gauge dynamometer showed that tangential cutting force Fz, feed force Fx would be increased and radius force Fy would be decreased after tool edge preparation.

Influence of Cutting Tool Edge Preparation on Cutting Force and Surface Integrity

2016 ◽  
Vol 836-837 ◽  
pp. 250-255
Author(s):  
Xue Feng Zhao ◽  
Lin He ◽  
Wei Liu ◽  
Wei Juan Zheng
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Practical Significance ◽  
Tool Edge ◽  
Radial Depth ◽  
Cutting Force Components ◽  
The Impact ◽  
Edge Preparation

The tool edge preparation has a significant influence on the quality of the workpiece surface, the stability of the cutting process and the tool life. In order to investigate the effect of the tool edge preparation, the impact on the cutting force components, the roughness and the residual stress is analyzed through the response surface methodology. The paper presents experimental results of turning tests with different edge radius and changing the cutting speed, the feed amount per tooth, the axial depth, and the radial depth. The research results will put forward theoretical value and practical significance to develop the processing technology of high-speed and efficient cutting, improve the metal cutting theory and prompt the development of the manufacture industry.

FEM of Saw Tooth Chip Formation under Different Cutting Edge

2010 ◽  
Vol 431-432 ◽  
pp. 417-420
Author(s):  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Yuan Sheng Zhai ◽  
Sheng Yuan Ji ◽  
Xing Fa Zhao
Keyword(s):  
Residual Stress ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Condition ◽  
Cutting Edge Preparation ◽  
Large Material ◽  
Edge Preparation ◽  
Generation Procedure

The generation procedure of saw tooth chip when PCBN tools orthogonal cutting hard steel GCr15 is emulated by FEM software ABAQUS in this study. The model effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation. The effects of cutting edge preparation on cutting force, cutting temperature and residual stress are analyzed. Results of FEM show that cutting edge preparation has a great impact on cutting procedure. Under the same cutting condition, cutting force, temperature and residual stress of sharp edge, honed edge and chamfered edge increases in turn, and three kinds of cutting edge have the same change rule in residual stress. Chamfered edge has a good temperature distributing, and it is the best edge preparation in hard cutting.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

scholarly journals Cutting Performance Evaluation of the Coated Tools in High-Speed Milling of AISI 4340 Steel

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3266 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
Rufeng Xu ◽  
...  
Keyword(s):  
Performance Evaluation ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Coated Tools ◽  
Coated Tool ◽  
Aisi 4340

The cutting performance of cutting tools in high-speed machining (HSM) is an important factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating, and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the serration and shear slip of the chips become more clear with the cutting speed. The lower cutting force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion. In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of the element diffusion.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

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