scholarly journals MEASUREMENT OF THE GEOMETRY OF MANUFACTURED DRILLS USING OPTICAL SCANNING

2021 ◽  
Vol 2021 (6) ◽  
pp. 5327-5333
Author(s):  
JAKUB HRBAL ◽  
◽  
JOZEF PETERKA ◽  
IVAN BURANSKY ◽  
JAN MILDE ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Great Influence ◽  
Helix Angle ◽  
Rake Angle ◽  
Machining Process ◽  
3D Scanner ◽  
Core Diameter ◽  
Measuring Device ◽  
Geometry Measurement ◽  
Tool Diameter

This article deals with the control of the geometry of manufactured tools. The geometry of the cutting tool has a great influence on the machining process. One of the processes of manufacturing cutting tools is grinding. Grinding cutting tools is a complex process after which it is necessary to check the geometry of the tools. Five solid drilling tools were manufactured for the experiment. The measured parameters were tool diameter, helix angle, point angle, rake angle, relief angle and core diameter of the cutting tools. The geometry of the cutting tools was measured on a non-contact structured 3D scanner ATOS Triple Scan light. The measurement results were evaluated using GOM software. The scanning results were compared with the geometry measurement on an optical measuring device Zoller Genius 3s. It has been found that the use of a non-contact structured 3D scanner is suitable for checking the geometry of cutting tools. Furthermore, the article deals with the roughness arising when grinding a sintered carbide flute.

scholarly journals Kekasaran permukaan pada pemesinan frais mikro Ti 6Al- 4V ELI (extra low intertitial)

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Endra Saputra ◽  
Suryadiwansa Harun ◽  
Eko Agus Supriyanto ◽  
Armulani Patihawa
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Titanium Material ◽  
Cutting Zone ◽  
Tool Diameter

One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micro machining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling tool diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm/rev, depth of cut 100 and 150 μm, which then do data processing using the method taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the depth of cut the most effect on surface roughness, the greater the tool diameter of the milling produced a smaller roughness value, this is inversely proportional to the depth of the cut. The lowest roughness value is 0,26 and the highest roughness value is 0,9. Keywords: Micro milling machining, titanium 6Al-4V ELI, surface roughness.

The Influence of Part Geometry on Changes of the Dynamic Geometric Parameters of Cutting Tools and Cutting Conditions when Contour Turning on CNC Lathes

2019 ◽  
Vol 889 ◽  
pp. 540-546
Author(s):  
Bui Ngoc Tuyen ◽  
Nguyen Chi Cong
Keyword(s):  
Cutting Tools ◽  
Rake Angle ◽  
Geometric Parameters ◽  
Cutting Conditions ◽  
Machining Process ◽  
Theoretical Development ◽  
Cutting Condition ◽  
Part Geometry ◽  
Mathematical Expressions ◽  
Set Up

Contour turning is a specific process of the machining on CNC lathes. In the finishing operation, to create the part profile, the turning tool must be moved in a trajectory of a complex flat curve (a toolpath) based on the part profile . The variation of feedrate vector on the toolpath according to the part profile in the machining process will results in changing dynamic geometric parameters of the cutting tool, which affects cutting conditions and machined part quality. This article presents the results of theoretical studies on the influence of part geometry on rake angle, clearance angle, approach angle and end cutting-edge angle of the turning tool. Based on the theoretical development, the authors also set up mathematical expressions that allow to define gouge-free cutting condition and the limit of feedtate for contour turning. An empirical model to define the influence of part geometry on the roughness of the part when countour turning on CNC lathe is also presented in this report.

scholarly journals Measurement of Micro Burr and Slot Widths through Image Processing: Comparison of Manual and Automated Measurements in Micro-Milling

Sensors ◽  
2021 ◽  
Vol 21 (13) ◽  
pp. 4432
Author(s):  
Fatih Akkoyun ◽  
Ali Ercetin ◽  
Kubilay Aslantas ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Image Processing ◽  
Computer Vision ◽  
Inconel 718 ◽  
Cutting Tools ◽  
Helix Angle ◽  
Rake Angle ◽  
Accurate Solution ◽  
Micro Milling ◽  
Burr Formation ◽  
Inconel 718 Alloy

In this study, the burr and slot widths formed after the micro-milling process of Inconel 718 alloy were investigated using a rapid and accurate image processing method. The measurements were obtained using a user-defined subroutine for image processing. To determine the accuracy of the developed imaging process technique, the automated measurement results were compared against results measured using a manual measurement method. For the cutting experiments, Inconel 718 alloy was machined using several cutting tools with different geometry, such as the helix angle, axial rake angle, and number of cutting edges. The images of the burr and slots were captured using a scanning electron microscope (SEM). The captured images were processed with computer vision software, which was written in C++ programming language and open-sourced computer library (Open CV). According to the results, it was determined that there is a good correlation between automated and manual measurements of slot and burr widths. The accuracy of the proposed method is above 91%, 98%, and 99% for up milling, down milling, and slot measurements, respectively. The conducted study offers a user-friendly, fast, and accurate solution using computer vision (CV) technology by requiring only one SEM image as input to characterize slot and burr formation.

scholarly journals Investigation of the Influence of Tool Rake Angles on Machining of Inconel 718

2021 ◽  
Vol 5 (3) ◽  
pp. 100
Author(s):  
Dongdong Xu ◽  
Liang Ding ◽  
Yang Liu ◽  
Jinming Zhou ◽  
Zhirong Liao
Keyword(s):  
Temperature Distribution ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Tools ◽  
Interaction Mechanism ◽  
Rake Angle ◽  
Machining Process ◽  
Rake Face ◽  
Machined Surface ◽  
Close Relationship

It is essential for superalloys (e.g., Inconel 718) to obtain an anticipated surface integrity after machining, especially for safety critical areas (e.g., aerospace). As one of the main characteristics for cutting tools, the rake angle has been recognized as a key factor that can significantly influence the machining process. Although there are large research interests and outcomes in the machining of nickel-based superalloys, most of them focus on the surface integrity and macroscale temperature observation, whereas the temperature distribution in the tool rake face is not clear. Thus, it is necessary to investigate the basic role of rake angles and the tool–workpiece interaction mechanism to determine the machining condition variations and surface integrity. In the present study, both experimental and numerical methods are employed to explore the cutting force, thermal distribution, and shear angles during the process and the metallurgy characteristics of the subsurface after machining, as well as the mechanical properties. The research has emphasized the importance of rake angles on both the cutting process and machined surface integrity, and has revealed the microscale temperature distribution in the tool rake face, which is believed to have a close relationship with the tool crater wear. In addition, it is clearly presented that the surface generated with positive rake angle tools generates the minimum subsurface deformation and less strain hardening on the workpiece.

Research of On-Machine Laser Measurement Method for Cutting Tools

2014 ◽  
Vol 1039 ◽  
pp. 223-228
Author(s):  
Xian Liang Chi ◽  
Xi Zhang ◽  
Fan Jiang
Keyword(s):  
High Precision ◽  
Cutting Tools ◽  
Machining Process ◽  
Laser Measurement ◽  
Process Technology ◽  
Detection Algorithms ◽  
Tool Shape ◽  
Photodiode Array ◽  
Measuring Tool ◽  
Tool Diameter

To successfully achieve high precision machining, process technology and on-machine measurement is essential. On-machine laser measurement will be widely used in industry because it is non-contacting, real-time and high-precision. However, proper method for tool shape monitoring and dimensional control are important to research. In this study, the measurement system consists of a laser light source and a quad photodiode array. And two different edge detection algorithms are introduced to determine the position of the tool edge accurately in order to measure the diameter of cutting tool and errors caused by tool runout. The experimental results verify the validity of measuring tool diameter and runout error.

Dynamic Behavior Study of Drill Bush Guide Plates from the Fixtures Structure

2015 ◽  
Vol 809-810 ◽  
pp. 760-765
Author(s):  
Neculai Eugen Seghedin ◽  
Dragoş Florin Chitariu
Keyword(s):  
Characteristic Feature ◽  
Direct Contact ◽  
Cutting Tools ◽  
Excitation Frequency ◽  
Machining Process ◽  
Resonance Phenomenon ◽  
Behavior Study ◽  
Specific Category ◽  
Tool Diameter ◽  
Size Adjustment

Fixtures are use to ensure the orientation and position of workpiece and cutting tools in machining systems. Drill bush guide / holder or are part of a specific category of elements and mechanisms, found in the fixtures structure: elements for size adjustment and guidance for cutting tools. These drill guide bush/ holder are used for guidance of drills, in order to ensure a certain position of the tool regarding the certain reference elements of the workpiece, or to increase the stiffness of drills, when the tool diameter is reduce, or when the surface of the machined workpiece is inclined. The drill bushes are placed in the fixture body, directly or through drill bush guide plates/ drill bush support plates. The characteristic feature of these bush plates is the console length. Sometimes, the bush guide plates can have large lengths that affect the dynamic stability. The bush guide plates are dynamically excited by the direct contact with the drill of the bush. If the natural frequency of vibration of the plate is equal or higher than the excitation frequency of the machining process, then the resonance phenomenon can appear.

Modeling and analysis of variable-core groove for integral cutting tools

2017 ◽  
Vol 232 (4) ◽  
pp. 471-479 ◽  
Author(s):  
Guochao Li ◽  
Jiao Liu ◽  
Honggen Zhou ◽  
Guizhong Tian ◽  
Lei Li
Keyword(s):  
Cross Section ◽  
Cutting Tools ◽  
Rake Angle ◽  
Graphical Analysis ◽  
Machining Process ◽  
Section Plane ◽  
Normal Section ◽  
Section Line ◽  
The Cross ◽  
Five Axis

With good stiffness, the helical groove with variable-core radius has been widely used for end mills, drills and other integral cutting tools. However, ground by five-axis grinder, its machining process is high cost and time consuming. Thus, this paper reports a graphical analysis method to obtain the structure parameters and geometric shapes of variable-core grooves with the known wheel geometry and position before the practical machining. The wheel movement during the machining process is firstly decomposed into three simple motions and modeled as a translation matrix. Then, a family of wheel surfaces is calculated and the groove cross section line is deduced by splitting the surfaces with a cross section plane. Accordingly, the normal section line of the groove is expressed by a series of scattered points, which are the intersections of the normal section plane and the helical curves generated by the points on the groove cross section line which moves along the wheel trajectory. All the mathematic models are programed by Matlab and verified by experiment. Finally, the key parameters of the variable-core groove, including the rake angle, groove width on the cross and normal sections and the departure distance between the cross and normal groove section lines, are analyzed from the tool bit to the hilt.

scholarly journals Finite Element Modeling of Brittle and Ductile Modes in Cutting of 3C-SiC

Crystals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1286
Author(s):  
Masud Alam ◽  
Liang Zhao ◽  
Napat Vajragupta ◽  
Junjie Zhang ◽  
Alexander Hartmaier
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Damage Model ◽  
Cutting Tools ◽  
Rake Angle ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Element Modeling ◽  
Brittle To Ductile Transition

Machining of brittle ceramics is a challenging task because the requirements on the cutting tools are extremely high and the quality of the machined surface strongly depends on the chosen process parameters. Typically, the efficiency of a machining process increases with the depth of cut or the feed rate of the tool. However, for brittle ceramics, this easily results in very rough surfaces or even in crack formation. The transition from a smooth surface obtained for small depths of cut to a rough surface for larger depths of cut is called a brittle-to-ductile transition in machining. In this work, we investigate the mechanisms of this brittle-to-ductile transition for diamond cutting of an intrinsically brittle 3C-SiC ceramic with finite element modeling. The Drucker–Prager model has been used to describe plastic deformation of the material and the material parameters have been determined by an inverse method to match the deformation behavior of the material under nanoindentation, which is a similar loading state as the one occurring during cutting. Furthermore, a damage model has been introduced to describe material separation during the machining process and also crack initiation in subsurface regions. With this model, grooving simulations of 3C-SiC with a diamond tool have been performed and the deformation and damage mechanisms have been analyzed. Our results reveal a distinct transition between ductile and brittle cutting modes as a function of the depth of cut. The critical depth of cut for this transition is found to be independent of rake angle; however, the surface roughness strongly depends on the rake angle of the tool.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Surgical Drilling: Design and Performance of an Improved Drill

1982 ◽  
Vol 104 (3) ◽  
pp. 245-252 ◽  
Author(s):  
S. Saha ◽  
S. Pal ◽  
J. A. Albright
Keyword(s):  
Compact Bone ◽  
Helix Angle ◽  
Rake Angle ◽  
Peak Temperature ◽  
Published Data ◽  
Drill Bit ◽  
Effective Removal ◽  
Split Point ◽  
And Performance ◽  
Twist Drills

The majority of twist drills used in orthopaedics are very similar to chisel pointed metal drilling bits. Modifications usually observed are reduction of the point angle to 90 deg and sometimes grinding of the entire cutting lip at 0 deg rake angle, which appeared to have been made arbitrarily without any advantage. We have attempted to design a surgical drill bit with the objective of minimization of the drilling thrust and temperature and effective removal of bone chips. Our results showed that the presence of the chisel edge was mainly responsible for increasing the thrust force and the temperature developed. The effects of a constant feed rate and thrust on the peak temperature were also examined. The combined effect of the helix and the point angles on the rake angle which in turn determines the cutting efficiency was analyzed for various types of surgical bits. Based on our results and previously published data from the literature an optimized drill bit was designed with a split point, a point angle of 118 deg, a parabolic flute, and a helix angle of 36 deg and its performance was compared with other existing surgical drill bits. For drilling in compact bone, the new design decreased the thrust load by 45 percent and the peak temperature rise by 41 percent. Simlar improvements were also recorded for drilling bone cement. The time of drilling a bone cortex was also significantly reduced and “walking” on the curved bone surface was eliminated and dimensional tolerance on hole sizes was improved. The new design is likely to reduce the time of surgery and also minimize the tissue damage.

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