Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

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Modeling Machining at High Speeds as a Fluid Mechanics Problem

ASME 2008 International Manufacturing Science and Engineering Conference, Volume 1 ◽

10.1115/msec_icmp2008-72082 ◽

2008 ◽

Author(s):

Roman V. Kazban ◽

James J. Mason

Keyword(s):

Fluid Mechanics ◽

Stagnation Point ◽

Potential Flow ◽

High Speed ◽

Material Behavior ◽

High Speed Machining ◽

Flow Solution ◽

High Speeds ◽

Ultra High Speed ◽

Very High

Even though many models for machining exist, most of them are for low-speed machining, where momentum is negligible and material behavior is well approximated by quasi-static plastic constitutive laws. In machining at high speeds, momentum can be important and the strain rate can be exceedingly high. For these reasons, a fluid mechanics approach to understanding high-speed, very high-speed, and ultra-high-speed machining is attempted here. Namely, a potential flow solution is used to model the behavior of the material around a sharp tool tip during machining at high speeds. It is carefully argued that the potential flow solution is relevant and can be used as a first approximation to model the behavior of a metal during high-speed, very high-speed, or ultra-high-speed machining events; and at a minimum, the potential flow solution is qualitatively useful in understanding mechanics of machining at high speeds and above. Interestingly, the flow solution predicts that there is a stagnation point on the rake face, not at the tool tip as is usually assumed. Because the stagnation point is not at the tool tip, the flow solution predicts a significant amount of deformation in the workpiece resulting in large residual strains that may lead to a temperature rise on the finished surface.

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Taguchi parametric study on the radial and tangential cutting forces in Dry High Speed Machining (DHSM)

Metallurgical and Materials Engineering ◽

10.30544/472 ◽

2020 ◽

Vol 26 (3) ◽

pp. 303-316

Author(s):

M. Hatami ◽

H. Safari

Keyword(s):

Titanium Alloy ◽

Cutting Force ◽

Feed Rate ◽

Parametric Study ◽

Cutting Forces ◽

High Speed ◽

Cutting Tools ◽

High Speed Machining ◽

Cutting Speeds

In this paper, L8 Taguchi array is applied to find the most important parameters effects on the radial and tangential cutting forces of a Ti–6Al-4V ELI titanium alloy in dry high speed machining (DHSM). The experiments are performed in four cutting speeds of 150, 200, 250, and 300 m/min and two feed rates of 0.03 and 0.06 mm/rev. Also, two cutting tools in types of XOMX090308TR-ME06 of uncoated (H25) and TiAlN+TiN coated (F40M) are used. Results confirm that to minimize the resultant cutting force and radial cutting force, utilizing the lower feed rate and higher cutting speeds were considered as the best levels of factors to reach to its goal.

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Implementation of ultra-high speed machining with an edge tool

10.1063/5.0036374 ◽

2021 ◽

Author(s):

V. M. Korneeva ◽

S. S. Korneev

Keyword(s):

High Speed ◽

High Speed Machining ◽

Ultra High Speed ◽

Edge Tool

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Very-high f/sub T/ and f/sub max/ silicon bipolar transistors using ultra-high-performance super self-aligned process technology for low-energy and ultra-high-speed LSI's

Proceedings of International Electron Devices Meeting ◽

10.1109/iedm.1995.499323 ◽

2002 ◽

Cited By ~ 7

Author(s):

M. Ugajin ◽

J. Kodate ◽

Y. Kobayashi ◽

S. Konaka ◽

T. Sakai

Keyword(s):

High Speed ◽

High Performance ◽

Bipolar Transistors ◽

Low Energy ◽

Process Technology ◽

Ultra High Speed ◽

Very High

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Tribological Influences of TiAlN Coating on Tool Wear for High-Speed Dry and Wet Machining of Steels

Manufacturing Engineering and Materials Handling Engineering ◽

10.1115/imece2004-61574 ◽

2004 ◽

Author(s):

Y. J. Lin ◽

Samir A. Khrais

Keyword(s):

High Speed ◽

High Speed Machining ◽

Structural Variations ◽

Edge Chipping ◽

Coated Tools ◽

Coated Tool ◽

Carbide Inserts ◽

Turning Test ◽

Cemented Carbide Inserts ◽

Cutting Speeds

The tribological influences of PVD-applied TiAlN coatings on the wear of cemented carbide inserts and the microstructure wear behaviors of the coated tools under dry and wet machining are investigated. The turning test was conducted with variable high cutting speeds ranging from 210 m/min to 410m/min. The analyses based on the experimental results lead to strong evidences that conventional coolant has a retarded effect on TiAlN coatings under high-speed machining. Microwear mechanisms identified in the tests through SEM micrographs include edge chipping, micro-abrasion, micro-fatigue, micro-thermal, and micro-attrition. These micro-structural variations of coatings provide structure-physical alterations as the measures for wear alert of TiAlN coated tool inserts under high speed machining of steels.

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Investigation of Temperature and Stress Distribution on High Speed Machining of Ti6Al4V and 316L Steel Biomaterials Using Explicit Dynamic Analysis

Materials Science Forum ◽

10.4028/www.scientific.net/msf.889.84 ◽

2017 ◽

Vol 889 ◽

pp. 84-89

Author(s):

Pandithevan Ponnusamy ◽

Mullapudi Joshi

Keyword(s):

Dynamic Analysis ◽

Mechanical Behaviour ◽

High Speed ◽

Cutting Speed ◽

Surgical Instruments ◽

Interface Temperature ◽

High Speed Machining ◽

316L Steel ◽

Explicit Dynamic ◽

Cutting Speeds

In high speed machining, to dynamically control the mechanical behaviour of the materials, it is essential to control temperature, stress and strain by appropriate speed, feed and depth of cut. In the present work, to predict the mechanical behaviour of Ti6Al4V and 316L steel bio-materials an explicit dynamic analysis with different cutting speeds was carried out. Orthogonal cutting of 316L steel and Ti6Al4V materials with 720 m/min, 900 m/min and 1200 m/min cutting speeds was performed, and the distribution of stress and temperature was investigated using Jonson-Cook material model. Additionally, the work aimed at determining the effect of cutting speed on work piece temperature, when cutting is carried out continuously. From the investigation, it was found that, while machining Ti6Al4V material, for the increase in cutting speed there was increase in tool-chip interface temperature. Specifically, this could found till the cutting speed 900 m/min. But, there was a decrease in tool-chip interface temperature for the increase in speed from 900 m/min to 1200 m/min. Similarly for 316L steel, the tool-chip interface temperature increased when increasing the cutting speed till 900 m/min. But reduction in temperature from 650 °C to 500 °C for steel and 1028 °C to 990 °C for Ti6Al4V were found, when the cutting speed increased from 900 m/min to 1200 m/min. The study can be used to conclude, at what temperature range the adoption of material with controlled shape and geometry is possible for potential applications like, prosthetic design and surgical instruments prior to fabrications.

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High Speed Machining: A Review from a Viewpoint of Chip Formation

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.188.578 ◽

2011 ◽

Vol 188 ◽

pp. 578-583 ◽

Cited By ~ 7

Author(s):

Toshiyuki Obikawa ◽

Masahiro Anzai ◽

Tsuneo Egawa ◽

Norihiko Narutaki ◽

Kazuhiro Shintani ◽

...

Keyword(s):

Tool Wear ◽

Life Span ◽

High Speed ◽

Cutting Speed ◽

Strong Nonlinearity ◽

High Speed Machining ◽

Cast Irons ◽

Sliding Test ◽

Cutting Experiments ◽

Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

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Impact of Tool Inserts in High Speed Machining of GFRP Composite Material

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.787.664 ◽

2015 ◽

Vol 787 ◽

pp. 664-668 ◽

Cited By ~ 1

Author(s):

K. Anand ◽

M.V. Siddharth ◽

K.S. Vijay Sekar ◽

S. Suresh Kumar

Keyword(s):

High Speed ◽

Removal Rate ◽

Research Work ◽

Aluminium Nitride ◽

High Speed Machining ◽

Feed Force ◽

Glass Fibre Reinforced Polymer ◽

Polymer Tube ◽

Cutting Speeds ◽

Titanium Aluminium

Composite materials are in-homogenous, anisotropic and cause high tool wear at high cutting speeds in machining. Industrial practices worldwide reveal a need to use high speed machining to achieve the desired material removal rate, surface finish and to reduce cost cutting. In this research work, impact of turning glass fibre reinforced polymer tube with two contrasting turning tool inserts such as titanium aluminium nitride and tungsten carbide have been analysed. The turning was conducted at low to high cutting conditions up to spindle speeds of 2000 rpm and feed rate of 0.446mm/rev. The cutting force, feed force were acquired with a strain gauge based dynamometer, the chip cross section was observed using scanning electron microscopy and the temperature was sensed with a infra red thermo sensor. The advanced titanium aluminium nitride insert shows better machining characteristics across cutting speeds.

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