scholarly journals Adaptive Control of the Metalworking Process With Using Sound Generated During Cutting

2021 ◽  
Author(s):  
Volodymyr Nahornyi ◽  
Anton Panda ◽  
Jan Valíček ◽  
Marta Harnicarova ◽  
Milena Kušnerová ◽  
...  
Keyword(s):  
Adaptive Control ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Close Correlation ◽  
Cutting Process ◽  
Machined Surface ◽  
Research Results ◽  
Online Mode ◽  
Operational Information ◽  
Monitoring And Diagnostics

Abstract The presented paper proposes a method of adaptive control of the metal cutting process based on the analysis and interpretation of recorded sound for the identification of the cutting process. The presented research results clearly demonstrated the efficiency of using the sound generated during cutting by CNC lathe 16 K20T1 for the adaptive metalworking control. The sound makes it possible to control the accuracy of the workpiece part geometry and the surface quality in the online mode. The online mode also makes it possible to make an informed decision about a timely interruption of the cutting process or the continuation of the process in the altered modes for its successful completion. As the research results presented in the paper show, there is a close correlation between the sound generated by cutting and the roughness of the surface being machined or the degree of wear of the cutting tool. The correlation between the sound and roughness of the machined surface is 0.94, whereas between the sound and wear of the cutting tool is 0.93. The paper aims to use the generated sound as operational information needed for adaptive control of the metal processing process and timely monitoring and diagnostics of the condition of processed materials using the precision index, newly introduced as the machining quality index.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

Role of energy consumption, cutting tool and workpiece materials towards environmentally conscious machining: A comprehensive review

2019 ◽  
Vol 234 (3) ◽  
pp. 335-354 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Ibrahim Deiab ◽  
Hossam Kishawy
Keyword(s):  
Energy Consumption ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Workpiece Material ◽  
Tool Materials ◽  
Wide Range ◽  
Cutting Operation

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication techniques to minimize the negative influence of cutting fluids on the environment. However, there is a need to enlarge the assessment domain for the metal-cutting process and other directly and indirectly associated practices such as enhancing sustainability through innovative methods for workpiece and cutting tool materials, and approaches to optimize energy consumption should also be explored. The aim of this article is to explore the role of energy consumption and the influence of workpiece and tool materials towards the sustainability of machining process. The article concludes that sustainability of the machining process can be improved by incorporating different innovative approaches related to the energy and tool–workpiece material consumptions.

Self-Excited Vibrations in Metal Cutting

1959 ◽  
Vol 81 (2) ◽  
pp. 183-186 ◽  
Author(s):  
Nathan H. Cook
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process

The basic mechanisms which cause self-excited vibrations of a cutting tool relative to the work are discussed in a qualitative manner. Similarly, mechanisms inherent in the cutting process which can damp or limit vibrations are discussed. Experiments are presented which are in agreement with the theory.

The use of assembled cutting tool with damping elements to reduce mechanical vibrations

2021 ◽  
Author(s):  
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Mill ◽  
Mechanical Vibrations ◽  
Machined Surface ◽  
High Speed Cutting ◽  
End Mills ◽  
Cutting Modes

Aspects of vibration reduction during machining on metal-cutting machines to improve the quality of machined surfaces at moderate and high-speed cutting modes are considered. End mills with damping elements made of different materials, which provide the control of tool rigidity, are developed. Keywords: vibrations, end mill, vibrations, machined surface, damping. [email protected]

Basic Mechanics of the Metal-Cutting Process

1944 ◽  
Vol 11 (3) ◽  
pp. A168-A175 ◽  
Author(s):  
M. Eugene Merchant
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Work Piece ◽  
Machining Operations ◽  
Work Done ◽  
Metal Work

Abstract The author presents a mathematical analysis of the geometry and mechanics of the metal-cutting process, covering two common types of geometry which occur in cutting. This analysis offers a key for the study of engineering problems in the field of metal cutting in terms of such fundamental quantities as strain, rate of shear, friction between chip and tool, shear strength of the metal, work done in shearing the metal and in overcoming friction, etc. The two cases covered are, in essence, that of a straight-edged cutting tool moving relative to the work-piece in a direction perpendicular to its cutting edge, termed “orthogonal cutting,” and that of a similar cutting tool so set that the cutting edge is oblique to the direction of relative motion of tool and work, termed “oblique cutting.” Equations are developed which permit the calculation of such quantities as those just enumerated from readily observable values. The theoretical findings are particularly applicable and significant in the case of present-day high-speed machining operations with sintered-carbide tools.

Increase of Firmness of the Metall-Cutting Tool on the Basis of Removal of Internal Tension in Replaceable Cutting Insert

2014 ◽  
Vol 682 ◽  
pp. 510-514 ◽  
Author(s):  
R.S. Chuykov ◽  
A.A. Mokhovikov ◽  
S.S. Chuykov
Keyword(s):  
Hard Alloy ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Technical Solution ◽  
Special Design ◽  
Preliminary Heating ◽  
Cutting Insert ◽  
Metal Cutting Tool

Results of research of types of the destruction caused by existence of internal tension in a tool firm alloy at production of the replaceable many-sided plates (RMSP) which can be removed by preliminary heating of cutting plates prior to cutting process are given in work. The new technical solution on realization of a method of preliminary heating of SMP is developed for removal of internal tension in the tool firm alloys (TFA), and also the special design of the metal-cutting tool is developed for increase of operability of hard-alloy SMP with preliminary heating.

Cutting Force and Friction Modelling in High Speed End-Milling

2015 ◽  
Author(s):  
Sunday J. Ojolo ◽  
Olumuwiya Agunsoye ◽  
Oluwole Adesina ◽  
Gbeminiyi M. Sobamowo
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece

Temperature field in metal cutting process is one of the most important phenomena in machining process. Temperature rise in machining directly or indirectly determines other cutting parameters such as tool life, tool wear, thermal deformation, surface quality and mechanics of chip formation. The variation in temperature of a cutting tool in end milling is more complicated than any other machining operation especially in high speed machining. It is therefore very important to investigate the temperature distribution on the cutting tool–work piece interface in end milling operation. The determination of the temperature field is carried out by the analysis of heat transfer in metal cutting zone. Most studies previously carried out on the temperature distribution model analysis were based on analytical model and with the used of conventional machining that is continuous cutting in nature. The limitations discovered in the models and validated experiments include the oversimplified assumptions which affect the accuracy of the models. In metal cutting process, thermo-mechanical coupling is required and to carry out any temperature field determination successfully, there is need to address the issue of various forces acting during cutting and the frictional effect on the tool-work piece interface. Most previous studies on the temperature field either neglected the effect of friction or assumed it to be constant. The friction model at the tool-work interface and tool-chip interface in metal cutting play a vital role in influencing the modelling process and the accuracy of predicted cutting forces, stress, and temperature distribution. In this work, mechanistic model was adopted to establish the cutting forces and also a new coefficient of friction was also established. This can be used to simulate the cutting process in order to enhance the machining quality especially surface finish and monitor the wear of tool.

Machining Characteristics of Leaded Steel

1960 ◽  
Vol 82 (2) ◽  
pp. 347-359 ◽  
Author(s):  
Fenton L. Bagley ◽  
Roy Mennell
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Work Piece ◽  
Two Dimensional ◽  
Life Data ◽  
Wide Range ◽  
Machining Characteristics ◽  
Lead Addition ◽  
Cutting Speeds

The effects of lead addition in alloy steel upon the metal-cutting process were explored over a wide range of conditions. In particular, a range of cutting speeds (from 50 to 800 fpm) and workpiece hardness (from 230 to 450 Bhn) were investigated on one work-piece material (4340) using principally a carbide (C-6) cutting tool. Orthogonal (two-dimensional) data was taken to describe the metal-cutting process, and tool-life data were obtained by running a typical production tool to failure at the various cutting conditions. Several mechanisms to explain experimental results, including lead acting as a lubricant, are discussed.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

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