scholarly journals Prediction of Chip Formation and Cutting Forces in Drilling with Curved Cutting Edge Drills(1st Report). Drill Geometry, Cutting Model and Energy Method.

2001 ◽  
Vol 67 (8) ◽  
pp. 1310-1315
Author(s):  
Kazuo KASAHARA ◽  
Akihiko HIROTA ◽  
Tuyoshi KAWASAKI
Keyword(s):  
Energy Method ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Cutting Model

scholarly journals A Mathematical Modeling to Predict the Cutting Forces in Microdrilling

2014 ◽  
Vol 2014 ◽  
pp. 1-11 ◽  
Author(s):  
Haoqiang Zhang ◽  
Xibin Wang ◽  
Siqin Pang
Keyword(s):  
Mathematical Modeling ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Force Model ◽  
Cutting Mechanism ◽  
Line Field ◽  
Slip Line Field ◽  
Cutting Model ◽  
Secondary Cutting

In microdrilling, because of lower feed, the microdrill cutting edge radius is comparable to the chip thickness. The cutting edges therefore should be regarded as rounded edges, which results in a more complex cutting mechanism. Because of this, the macrodrilling thrust modeling is not suitable for microdrilling. In this paper, a mathematical modeling to predict microdrilling thrust is developed, and the geometric characteristics of microdrill were considered in force models. The thrust is modeled in three parts: major cutting edges, secondary cutting edge, and indentation zone. Based on slip-line field theory, the major cutting edges and secondary cutting edge are divided into elements, and the elemental forces are determined by an oblique cutting model and an orthogonal model, respectively. The thrust modeling of the major cutting edges and second cutting edge includes two different kinds of processes: shearing and ploughing. The indentation zone is modeled as a rigid wedge. The force model is verified by comparing the predicted forces and the measured cutting forces.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

A smooth particle hydrodynamic model for two-dimensional numerical simulation of Ti–6Al–4V serrated chip deformation based on TANH constitutive law

2018 ◽  
Vol 233 (9) ◽  
pp. 3004-3017 ◽  
Author(s):  
Weilong Niu ◽  
Rong Mo ◽  
Huibin Sun ◽  
Balachander Gnanasekaran ◽  
Yihui Zhu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Chip Formation ◽  
Cutting Forces ◽  
Damage Model ◽  
Smooth Particle Hydrodynamic ◽  
Chip Morphology ◽  
Constitutive Law ◽  
Cutting Process ◽  
Serrated Chip ◽  
Cutting Model

The saw-tooth chip formation is one of the main machining characteristics in cutting of titanium alloys. The numerical simulation of saw-tooth chip formation, however, is still not accurate, since most of these numerical simulation models are based on traditional finite element method, which have difficulties in handling extremely large deformation that always occurs in the cutting process. Furthermore, these models adopt the Johnson–Cook damage constitutive law that is implemented in commercial codes such as ABAQUS® and LS-DYNA® to describe the dynamic mechanical properties of material, but Johnson–Cook damage constitutive law cannot account for the material of behavior due to strain softening and the dynamic recrystallization mechanism that occurs in the cutting process of Ti–6Al–4. Therefore, this work introduces a material constitutive model named hyperbolic tangent (TANH) and an improved smooth particle hydrodynamics method, and then develops an improved cutting model for Ti–6Al–4V titanium alloy through our in-house code to predict saw-tooth chip morphology and cutting forces. When compared to the experiments and Johnson–Cook damage model, the improved cutting model better explains and predicts the shear localized saw-tooth chip deformation as well as cutting forces.

Investigation of Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 117-119 ◽  
pp. 1465-1470
Author(s):  
Sayed Mohamad Nikouei ◽  
Mohammad Ali Kouchakzadeh ◽  
R. Yousefi ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used to predict the shear plane angles and cutting forces in machining of Al/SiCpMMC. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results show that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

Development of Micro Milling Machine and Experimental Study on Meso Scale Milling

2007 ◽  
Author(s):  
Chengfeng Li ◽  
Xinmin Lai ◽  
Hongtao Li ◽  
Linfa Peng ◽  
Jun Ni
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Three Dimensional ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Machine ◽  
Meso Scale

This paper develops a three-axis micro milling machine for manufacturing meso-scale components and products. This machine utilizes high-speed miniature spindle to obtain appropriate cutting velocities, and three precision linear stages with 50 nm feed resolution to supply the relative motion. The PMAC2 controller is used to control three axes simultaneously, and a piezoelectric dynamometer is mounted on the X-Y stages to measure three-dimensional cutting forces for the real-time measurement and feedback. More than 200 cutting experiments of end milling operations are performed on the developed machine. When the machined feature ranges at meso scale, the characteristics and phenomena in milling process will heavily differ from those of conventional scale milling due to the size effects. The critical differences at meso scale arise from the breakdown of the assumptions of negligible edge radius effects. The roundness of cutting edge and the runout of spindle have a crucial impact on the chip formation process and the characteristics of cutting forces. The roundness of cutting edge also induces the existence of the minimum chip thickness and the intermittency of the chip formation at a low feed per tooth.

Finite Element Analysis of Precision Hard Cutting Using Different Cutting Edge Preparation

2007 ◽  
Vol 10-12 ◽  
pp. 353-358 ◽  
Author(s):  
Yu Wang ◽  
Fu Gang Yan ◽  
P. Wang ◽  
Cai Xu Yue ◽  
Xian Li Liu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Published Data ◽  
Element Analysis ◽  
Hardened Steels ◽  
Cutting Edge Preparation ◽  
Cutting Model ◽  
Edge Preparation

Machining hardened steels has become an important manufacturing process, particularly in the automotive and bearing industries. Hardened steel GCr15 with its harness between HRC50 and HRC65 is one kind of more difficult machining material. Abrasive processes such as grinding have typically been required to machine hardened steels, but advances in machine tools and a new cutting material of polycrystalline cubic boron nitride (PCBN) have allowed hard turning on modern lathes to seems to gain an ever increasing industrial acceptance as an economically and environmentally friendly alternative to many grinding applications. In this paper, based on large deformation theory and updated Lagrangian procedure, a coupled thermo-mechanical plane strain orthogonal precision cutting model with general finite element analysis software is developed to the influence of cutting edge preparation on the cutting of GCr15 with PCBN tool, such as cutting forces, shear angle, and cutting temperature. The three major designs of cutting edge preparation are used on most commercial cutting inserts: a) sharp edge, b) honed edge, and c) chamfer edge. The friction between the tool and the chip is assumed to follow a shear model and the local adaptive remeshing technique is used for the formation of chip. The calculated principle cutting forces are compared with published data and found to be in good agreement. The simulation results can be used as a practical tool both by researchers and toolmakers to design new tools with rational tool edge and to optimize the cutting process.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

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