scholarly journals Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

2021 ◽  
Vol 11 (22) ◽  
pp. 10737
Author(s):  
Yucheng Li ◽  
Xu Zhang ◽  
Cui Wang
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Cutting Forces ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Contact Length ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Elliptical Vibration ◽  
Three Phase

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force.

Research on Physical Simulation of Virtual CNC Turning

2012 ◽  
Vol 510 ◽  
pp. 50-53
Author(s):  
Chun Lei Li
Keyword(s):  
Steady State ◽  
Prediction Model ◽  
Cutting Force ◽  
Cutting Forces ◽  
Physical Simulation ◽  
Work Piece ◽  
Machining Error ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Cnc Turning

Sources and measurement of cutting forces are studied to establish the steady-state cutting force prediction model. Modeling of work piece machining error is analyzed, a simplified process coordinate system is established, and the mathematical solving model of machining error within the work piece is given. The cutting force due to work piece bending deformation is studied, a work piece deformation factor error model is established based on steady-state cutting force and the prediction simulation of cutting forces and machining error is achieved.

Modeling and investigation of cutting force for SiCp/Al composites during ultrasonic vibration-assisted turning

2021 ◽  
pp. 095440892110607
Author(s):  
Jieqiong Lin ◽  
Chao Wang ◽  
Mingming Lu ◽  
Jiakang Zhou ◽  
Shixin Zhao ◽  
...  
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Depth Direction ◽  
Experimental Values

The machining process of SiCp/Al composites is considerably difficult because of the addition of ceramic particles. As an effective machining method, ultrasonic vibration-assisted turning is used to process SiCp/Al composites, which can effectively reduce the cutting force, improve the surface quality, and reduce the tool wear. This study developed a cutting force prediction model for ultrasonic vibration-assisted turning of SiCp/Al composites, which comprehensively considers the instantaneous depth of cut and the instantaneous shear angle. This model divides the cutting force into the chip formation force considering the instantaneous depth of cut, the friction force considering the influence of SiC particles at tool-chip interface, the particle fracture force, and the ultrasonic impact force in the cutting depth direction. By comparing the predicted value of the main cutting force with the experimental values, the results present the same trend, which verifies the feasibility of the cutting force prediction model. In addition, the influence of vibration amplitude, depth of cut, and cutting speed on the main cutting force is analyzed. The systematic cutting experiments show that ultrasonic vibration-assisted turning can significantly reduce the cutting force and improve the machinability of SiCp/Al composites.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

Analysis of Cutting Force in Elastomer End-Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 958-963
Author(s):  
Koji Teramoto ◽  
◽  
Takahiro Kunishima ◽  
Hiroki Matsumoto
Keyword(s):  
Parameter Identification ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
The Stability

Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

scholarly journals Cutting Force Modeling and Experimental Study for Ball-End Milling of Free-Form Surfaces

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Zhaozhao Lei ◽  
Xiaojun Lin ◽  
Gang Wu ◽  
Luzhou Sun
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Chip Thickness ◽  
Free Form ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Undeformed Chip Thickness ◽  
Free Form Surface ◽  
Free Form Surfaces

In order to improve the machining quality and efficiency and optimize NC machining programming, based on the existing cutting force models for ball-end, a cutting force prediction model of free-form surface for ball-end was established. By analyzing the force of the system during the cutting process, we obtained the expression equation of the instantaneous undeformed chip thickness during the milling process and then determined the rule of the influence of the lead angle and the tilt angle on the instantaneous undeformed chip thickness. It was judged whether the cutter edge microelement is involved in cutting, and the algorithm flow chart is given. After that, the cutting force prediction model of free-form surface for ball-end and pseudocodes for cutting force prediction were given. MATLAB was used to simulate the prediction force model. Finally, through the comparative analysis experiment of the measured cutting force and the simulated cutting force, the experimental results are basically consistent with the theoretical prediction results, which proves that the model established in this paper can accurately predict the change of the cutting force of the ball-end cutter in the process of milling free-form surface, and the error of the cutting force prediction model established in this paper is reduced by 15% compared with the traditional cutting force prediction model.

Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes

2011 ◽  
Vol 223 ◽  
pp. 85-92 ◽  
Author(s):  
Balázs Tukora ◽  
Tibor Szalay
Keyword(s):  
Cutting Force ◽  
Real Time ◽  
Cutting Forces ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Work Piece ◽  
Processing Unit ◽  
Cutting Force Prediction ◽  
Force Prediction

In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

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