209. Metalworking Fluid Exposures in Several Metal Machining Industries

In the practice of processing of metals by cutting it is necessary to overcome the vibration of the cutting tool, the processed detail and units of the machine tool. These vibrations in many cases are an obstacle to increase the productivity and quality of treatment of details on metal-cutting machine tools. Vibration at cutting of metals is a very diverse phenomenon due to both it’s nature and the form of oscillatory motion. The most general classification of vibrations at cutting is a division them into forced vibration and autovibrations. The most difficult to remove and poorly investigated are the autovibrations, i.e. vibrations arising at the absence of external periodic forces. The autovibrations, stipulated by the process of cutting on metalcutting machine are of two types: the low-frequency autovibrations and high-frequency autovibrations. When the low-frequency autovibration there appear, the cutting process ought to be terminated and the cause of the vibrations eliminated. Otherwise, there is a danger of a break of both machine and tool. In the case of high-frequency vibration the machine operates apparently quiently, but the processed surface feature small-sized roughness. The frequency of autovibrations can reach 5000 Hz and more.

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3D Finite Element Simulation for Turning of Hardened 45 Steel

Recent Patents on Engineering ◽

10.2174/1872212112666180522082717 ◽

2019 ◽

Vol 13 (2) ◽

pp. 181-188

Author(s):

Meng Liu ◽

Guohe Li ◽

Xueli Zhao ◽

Xiaole Qi ◽

Shanshan Zhao

Keyword(s):

Finite Element ◽

Finite Element Model ◽

Cutting Force ◽

Finite Element Simulation ◽

Orthogonal Experiment ◽

Element Model ◽

3D Finite Element ◽

Element Simulation ◽

Metal Machining ◽

Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

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Metal Machining—Recent Advances, Applications, and Challenges

Metals ◽

10.3390/met11040580 ◽

2021 ◽

Vol 11 (4) ◽

pp. 580

Author(s):

Francisco J. G. Silva

Keyword(s):

Surface Finish ◽

Manufacturing Process ◽

Dimensional Accuracy ◽

Machining Process ◽

High Dimensional ◽

Manufacturing Processes ◽

Recent Advances ◽

Metal Machining ◽

Rapid Manufacture

Though new manufacturing processes that revolutionize the landscape regarding the rapid manufacture of parts have recently emerged, the machining process remains alive and up-to-date in this context, always presenting itself as a manufacturing process with several variants and allowing for high dimensional accuracy and high levels of surface finish [...]

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