Predicting Cutting Forces for Oblique Machining Conditions

1982 ◽  
Vol 196 (1) ◽  
pp. 141-148 ◽  
Author(s):  
G C I Lin ◽  
P Mathew ◽  
P L B Oxley ◽  
A R Watson
Keyword(s):  
Thermal Properties ◽  
Flow Stress ◽  
Cutting Force ◽  
Plane Strain ◽  
Cutting Forces ◽  
Material Flow ◽  
Cutting Conditions ◽  
Orthogonal Plane ◽  
Simplifying Assumptions ◽  
Experimental Cutting

Using orthogonal (plane strain) machining theory together with certain simplifying assumptions based on experimental observations it is shown how the three components of cutting force in oblique machining can be predicted from a knowledge of the work material flow stress and thermal properties and the cutting conditions. A comparison of predicted and experimental cutting force results is given.

The Mechanical Behavior of Zinc During Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 172-178 ◽  
Author(s):  
Robin Stevenson ◽  
David A. Stephenson
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Mechanical Behavior ◽  
Feed Rate ◽  
Cutting Forces ◽  
Material Flow ◽  
Cutting Tool ◽  
Cutting Conditions ◽  
Extrapolation Method ◽  
Compression Tests

It is well known that a nonzero force is obtained when cutting forces measured at different feed rates but otherwise constant cutting conditions are extrapolated to zero feed rate. In the literature, this nonzero intercept has been attributed to a ploughing effect associated with the finite sharpness of the cutting tool. However, the standard extrapolation method does not account for other variables such as strain, strain rate and temperature which also vary with feed rate and influence the work material flow stress. In this paper, the apparent flow stresses measured in high and low speed machining tests on zinc are compared with the flow stresses measured in compression tests. The results show that the flow stress measured in cutting is consistent with that measured in compression when all deformation variables are properly accounted for and that, contrary to the results obtained using the extrapolation approach, the ploughing force is negligible.

Prediction of Cutting Forces and Built-Up Edge Formation Conditions in Machining With Oblique Nose Radius Tools

1996 ◽  
Vol 210 (5) ◽  
pp. 457-469 ◽  
Author(s):  
J A Arsecularatne ◽  
R F Fowle ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Thermal Properties ◽  
Cutting Forces ◽  
Material Flow ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Tool Geometries ◽  
Formation Conditions ◽  
Semi Empirical ◽  
Cutting Speeds ◽  
Good Agreement

A semi-empirical machining theory is described for predicting cutting forces and temperatures for oblique nose radius tools from cutting conditions and a knowledge of work material flow stress and thermal properties. Predictions are made for a range of cutting speeds and tool geometries. It is shown how the cutting conditions giving a built-up edge can be determined from the predicted cutting temperatures. A comparison between predicted and experimental results shows good agreement.

Turning Force Prediction of AISI 4130 Considering Dynamic Recrystallization

2017 ◽  
Author(s):  
Zhipeng Pan ◽  
Yixuan Feng ◽  
Xia Ji ◽  
Steven Y. Liang
Keyword(s):  
Grain Size ◽  
Flow Stress ◽  
Dynamic Recrystallization ◽  
Analytical Model ◽  
Cutting Forces ◽  
Material Flow ◽  
Explicit Calculation ◽  
Material Microstructure ◽  
Machining Forces ◽  
Aisi 4130

Thermal mechanical loadings in machining process would promote material microstructure changes. The material microstructure evolution, such as grain size evolution and phase transformation could significantly influence the material flow stress behavior, which will directly affect the machining forces. An analytical model is proposed to predict cutting forces during the turning of AISI 4130 steel. The material dynamic recrystallization is considered through Johnson-Mehl-Avrami-Kolmogorov (JMAK) model. The explicit calculation of average grain size is provided in an analytical model. The grain size effect on the material flow stress is considered by introducing the Hall-Petch relation into a modified Johnson-Cook model. The cutting forces prediction are based on Oxley’s contact mechanics with consideration of mechanical and thermal loads. The model is validated by comparing the predicted machining forces with experimental measurements.

A Mechanistic Model of Cutting Forces in Micro-End-Milling With Cutting-Condition-Independent Cutting Force Coefficients

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Han Ul Lee ◽  
Dong-Woo Cho ◽  
Kornel F. Ehmann
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Cutting Conditions ◽  
Thickness Effect ◽  
Force Model ◽  
Cutting Force Coefficients ◽  
Force Coefficients ◽  
Micro End Milling ◽  
Cutting Mechanisms

Complex three-dimensional miniature components are needed in a wide range of industrial applications from aerospace to biomedicine. Such products can be effectively produced by micro-end-milling processes that are capable of accurately producing high aspect ratio features and parts. This paper presents a mechanistic cutting force model for the precise prediction of the cutting forces in micro-end-milling under various cutting conditions. In order to account for the actual physical phenomena at the edge of the tool, the components of the cutting force vector are determined based on the newly introduced concept of the partial effective rake angle. The proposed model also uses instantaneous cutting force coefficients that are independent of the end-milling cutting conditions. These cutting force coefficients, determined from measured cutting forces, reflect the influence of the majority of cutting mechanisms involved in micro-end-milling including the minimum chip-thickness effect. The comparison of the predicted and measured cutting forces has shown that the proposed method provides very accurate results.

scholarly journals A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes

2015 ◽  
Vol 2 (4) ◽  
pp. 233-247 ◽  
Author(s):  
Yung-Chou Kao ◽  
Nhu-Tung Nguyen ◽  
Mau-Sheng Chen ◽  
Shyh-Chour Huang
Keyword(s):  
Cutting Force ◽  
Experimental Method ◽  
Linear Function ◽  
Cutting Forces ◽  
Cutting Conditions ◽  
End Mill ◽  
Ball End Mill ◽  
Cutting Force Coefficients ◽  
Force Coefficients

Abstract In this paper, the cutting force calculation of ball-end mill processing was modeled mathematically. All derivations of cutting forces were directly based on the tangential, radial, and axial cutting force components. In the developed mathematical model of cutting forces, the relationship of average cutting force and the feed per flute was characterized as a linear function. The cutting force coefficient model was formulated by a function of average cutting force and other parameters such as cutter geometry, cutting conditions, and so on. An experimental method was proposed based on the stable milling condition to estimate the cutting force coefficients for ball-end mill. This method could be applied for each pair of tool and workpiece. The developed cutting force model has been successfully verified experimentally with very promising results. Highlights By investigation of the stable cutting conditions in milling process, the linear function of average cutting force and feed per flute was successfully verified. A combined theoretical-experimental method was proposed with an effective model for the determination of cutting force coefficients in ball-end mill process.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Force Modeling in Laser-Assisted Microgrooving Including the Effect of Machine Deflection

2009 ◽  
Vol 131 (1) ◽  
Author(s):  
Ramesh Singh ◽  
Shreyes N. Melkote
Keyword(s):  
Flow Stress ◽  
Cutting Force ◽  
Cutting Forces ◽  
Laser Power ◽  
Continuous Wave ◽  
Dimensional Accuracy ◽  
Thermal Softening ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model

Laser assisted mechanical micromachining is a process that utilizes highly localized thermal softening of the material by continuous wave laser irradiation applied simultaneously and directly in front of a miniature cutting tool in order to produce micron scale three-dimensional features in difficult-to-machine materials. The hybrid process is characterized by lower cutting forces and deflections, fewer tool failures, and potentially higher material removal rates. The desktop-sized machine used to implement this process has a finite stiffness and deflects under the influence of the cutting forces. The deflections can be of the same order of magnitude as the depth of cut in some cases, thereby having a negative effect on the dimensional accuracy of the micromachined feature. As a result, selection of the laser and cutting parameters that yield the desired reduction in cutting forces and deflection, and consequently an improvement in dimensional accuracy, requires a reliable cutting force model. This paper describes a cutting force model for the laser-assisted microgrooving process. The model accounts for the effect of elastic deflection of the machine X-Y stages on the forces and accuracy of the micromachined feature. The model combines an existing slip-line field based force model with a finite element based thermal model of laser heating and a constitutive material flow stress model to account for thermal softening. Experiments are carried out on H-13 steel (42 HRC (hardness measured on the Rockwell ‘C’ scale)) to validate the force model. The effects of process parameters, such as laser power and cutting speed, on the forces are also analyzed. The model captures the effect of thermal softening and indicates a 66% reduction in the shear flow stress at 35 W laser power. The cutting force and depth of cut prediction errors are less than 20% and 10%, respectively, for most of the cases examined.

Cutting Mechanism of Resin Impregnated Sintered Iron

2010 ◽  
Vol 638-642 ◽  
pp. 1836-1841 ◽  
Author(s):  
Kunio Okimoto
Keyword(s):  
Plastic Deformation ◽  
Thermal Properties ◽  
Flow Stress ◽  
Cutting Force ◽  
Coefficient Of Friction ◽  
Work Hardening ◽  
Fracture Strain ◽  
Cutting Mechanism ◽  
Sintered Iron ◽  
Resin Impregnation

Impregnating resin into the open pores of a sintered iron compact is well known to improve the machinability of the compact. However, the causes of this phenomenon require further investigation. The purpose of this study is to clarify the main cause of the improvement in machinability on resin impregnation. In this study, sintered iron was machined and the influences of resin impregnation on its thermal properties, coefficient of friction, and flow stress (deformation resistance) were investigated. The results indicate that the great improvement in machinability produced by resin impregnation is mainly due to a reduction in the plastic deformation (fracture strain) for chip generation, lowering the degree of work hardening and consequently reducing the cutting force required.

Experimental Cutting Force Properties on Interpenetrating Network Composites with Double Metal Phases

2014 ◽  
Vol 680 ◽  
pp. 123-126
Author(s):  
Ning Fan ◽  
Yong Yu ◽  
Yang Bai
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Processing System ◽  
Cutting Parameters ◽  
Interpenetrating Network ◽  
Resistance Strain Gage ◽  
Machining Quality ◽  
Experimental Cutting ◽  
Data Acquisition And Processing ◽  
Metal Phases

Cutting properties of interpenetrating network composites are important to ensure machining quality. The cutting force signals were measured by resistance strain gage of octagonal ring style and data acquisition and processing system. The results show that the cutting forces are affected by cutting conditions. To average cutting forces of interpenetrating network composites, the laws are basically consistent with that of the traditional materials. Because of the reinforced phase, the sudden cutting forces arise in cutting process whose values are relate to cutting parameters and reinforced phase dimensions.

Prediction of High Speed Machining Cutting Forces Using a Variable Flow Stress Machining Theory

2011 ◽  
Vol 188 ◽  
pp. 128-133 ◽  
Author(s):  
Philip Mathew
Keyword(s):  
Flow Stress ◽  
Cutting Forces ◽  
High Speed ◽  
Experimental Results ◽  
The Other ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Variable Flow ◽  
Machining Conditions

A variable flow stress machining theory is described where it is used to predict the cutting forces associated with High Speed Machining (HSM) process. The predicted and experimental results for different materials and different cutting conditions are presented and compared and it is shown that the theory developed is capable of predicting the cutting forces and the other parameters associated with the HSM process. The extension of the theory to HSM has been successful within the machining conditions presented here in this paper. Further work is necessary to improve this theory further.

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