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.

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.

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.

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.

Prediction of Chip Flow Direction and Cutting Forces in Oblique Machining with Nose Radius Tools

1995 ◽  
Vol 209 (4) ◽  
pp. 305-315 ◽  
Author(s):  
J A Arsecularatne ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Chip Flow ◽  
Wide Range ◽  
Predicted Values ◽  
Edge Based

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and the cutting conditions, namely feed and depth of cut. By defining an equivalent cutting edge based on the chip flow direction it is then shown how cutting forces can be predicted given the work material's flow stress and thermal properties. A comparison between experimental results obtained from bar turning tests and predicted values for a wide range of tool geometries and cutting conditions shows good agreement.

The Experimental Investigation of the Effects of Different Chip Breaker Forms on the Cutting Forces

2007 ◽  
Vol 23 ◽  
pp. 191-194 ◽  
Author(s):  
Huseyin Gürbüz ◽  
Adem Kurt ◽  
I. Korkut ◽  
Ulvi Şeker
Keyword(s):  
Experimental Investigation ◽  
Cutting Forces ◽  
Manufacturing Industry ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Test Results ◽  
Workpiece Material ◽  
Chip Breaker ◽  
Cutting Speeds

The objective of this paper is experimentally investigation of the effects of different chip breaker forms on the cutting forces according to various cutting parameters. AISI 1050 workpiece material, most used material in the manufacturing industry, and SNMG 120408R inserts and PSBNR 2525M12 tool holder have 75° approaching angle according to ISO 3685 are used in the experiments. Seven groups chip breaker form were used in the tests. The chip breaker forms are the coated inserts MA, SA, MS, GH and standard, and the uncoated inserts MS and standard. These inserts are Mitsubishi UC 6010 and UTI20T grade; correspond to ISO P30 and P15 grade, respectively. Machining tests were carried out by using five levels of cutting speeds (150, 200, 250, 300, 350 m/min), three levels of feed rate (0.15, 0.25, 0.35 mm/rev) and two levels of depth of cut (1.6, 2.5 mm). Cutting forces were measured using Kistler dynamometer. The test results show that the highest cutting force values were measured on SA, GH, MA forms, respectively. Complex chip breaker forms cause the increase of the cutting forces. Although the cutting forces on the uncoated inserts were partly small in light cutting conditions, it has increased on the uncoated inserts in heavy cutting conditions compared to coated inserts.

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.

Monitoring of Wear Land Width of Diamond Tool Cutting Edge with Large Nose Radius in Ultra-Precision Cutting Using Static Cutting Forces

2014 ◽  
Vol 1017 ◽  
pp. 696-702
Author(s):  
Eiji Kondo ◽  
Ryuichi Iwamoto ◽  
Yuya Kobaru
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Diamond Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Land Width

Large wear of diamond tools for ultra-precision cutting of soft metals deteriorates quality of machined surface, and the worn tools have to be replaced with new tools when the tool wear reaches limited wear land width of cutting edge generating finished surface. However, it is difficult to predict the tool life since all cutting tools have individual tool life. Therefore, the purpose of this study is to estimate wear land width of cutting edge of a single crystal diamond tool having large nose radius by using static cutting forces during machining. As a result of the cutting tests and measurements, it was found that the ratio of thrust force to principal force had good relation with the ratio of flank wear land area to cutting cross section area. Furthermore, according to some detailed observation of flank wear, width of flank wear land was greatly related to uncut chip thickness obtained under different cutting conditions and it was found that width of flank wear land could be estimated by measured static cutting forces and cutting conditions.

Determination of the Temperature of a Machined Surface

1998 ◽  
Vol 120 (2) ◽  
pp. 259-263 ◽  
Author(s):  
T. H. Chu ◽  
J. Wallbank
Keyword(s):  
Mild Steel ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Nose Radius ◽  
Machined Surface ◽  
Cutting Speeds

A technique for measuring temperature close to the primary cutting edge in turning has been developed. The cutting temperatures of a 0.16 percent carbon bright drawn mild steel, have been measured for a range of cutting speeds and feedrates at a constant depth of cut. Tool nose radius was also varied. The correlations for the workpiece temperature of cutting speed and feedrate have been developed. The results show that the temperature correlates well with cutting speed and feedrate but the nose radius has little effect. Cutting forces were measured by a dynamometer and these were used to find the non zero forces at zero feedrate. These forces have been related to the deformation of the work material near the cutting edge of the tool and a method for calculating the cutting temperatures from these has been proposed.

Drilling Thrust and Torque Prediction of Viscoplastic Materials

2006 ◽  
Author(s):  
Hossein Vaghefpour ◽  
Ali Nayebi
Keyword(s):  
Shear Zone ◽  
Cutting Forces ◽  
Material Flow ◽  
Thrust Force ◽  
Orthogonal Cutting ◽  
Thermomechanical Properties ◽  
Twist Drill ◽  
Proposed Model ◽  
Thrust And Torque ◽  
Good Agreement

A model for drilling of viscoplastic materials is presented. An analytical model is developed for predicting thrust force and torque in the drilling with a twist drill. The thermomechanical properties are accounted for describing the material flow in the primary shear zone and at the element-chip interface. A temperature friction law is introduced. The approach is based on the representing the cutting forces along the cutting lips as a series of oblique elements. Similarly, cutting in the chisel region is treated as orthogonal cutting with different speeds depending on the radial location. The section forces obtained by the model are combined to determine the overall thrust force and drilling torque. The results of the proposed model are compared with experimental results and a good agreement is obtained.

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