scholarly journals Experimental Study on a “Snake-Type” Vibration Cutting Method for Cutting Force and Cutting Heat Reductions

Biomimetics ◽  
2019 ◽  
Vol 4 (3) ◽  
pp. 57 ◽  
Author(s):  
Xiangyu Zhang ◽  
Zhenlong Peng ◽  
Deyuan Zhang
Keyword(s):  
Cutting Force ◽  
Surface Integrity ◽  
Cutting Temperature ◽  
Target Surface ◽  
Ultrasonic Frequency ◽  
Heat Accumulation ◽  
Cutting Method ◽  
Vibration Cutting ◽  
Residual Stress State ◽  
Cutting Heat

Cutting is the foundation of manufacturing in industry. The main cutting objects include metals, ceramics, glasses, compositions, and even biological materials such as tissues and bones. The special properties of each material such as hardness, ductility, brittleness, and heat conductivity lead to either a large cutting force or a high cutting temperature. Both of these factors result in poor machinability due to rapid tool wear or break or unsatisfactory surface integrity of the material finishing surface using the conventional cutting (CC, conventional cutting) types. In nature, snakes have their own way of reducing heat accumulation on their body when moving on the hot desert surface. They move forward along an “S”-type path, so that the bottom of their body separates from the desert intermittently. In this way, the separation interval both reduces the cutting heat accumulations and effectively achieves cooling by allowing the air to go through. In addition, the acceleration of Odontomachus monticola’s two mandibles when striking a target can reach 71,730 g m/s2 within 180 ms, which can easily break the target surface by the transient huge impact. Therefore, based on a snake’s motion on the desert surface and Odontomachus monticola’s striking on the target surface, respectively, an ultrasonic-frequency intermittent cutting method, also called “snake-type” vibration cutting (SVC, snake-type vibration cutting), was proposed in this study. First, its bionic kinematics were analyzed, then the SVC system’s design was introduced. Finally, cutting experiments were conducted on a common and typical difficult-to-cut material, namely titanium alloys. Cutting force, cutting temperature, and the surface integrity of the material finishing surface were measured, respectively. The results demonstrated that, compared to conventional cutting methods, SVC achieved a maximum of 50% and 30% reductions of cutting force and cutting temperature, respectively. Moreover, the surface integrity was improved both in surface roughness and residual stress state.

scholarly journals Research on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal Ultrasonic Vibration Assisted Milling

2021 ◽  
Author(s):  
Weibo Xie ◽  
Xikui Wang ◽  
Erbo Liu ◽  
Jian Wang ◽  
Xiaobin Tang ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Surface Integrity ◽  
Rotational Speed ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Surface Residual Stress ◽  
Deformation Layer ◽  
Vibration Milling

Abstract In order to study the influence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a significant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the influence of ultrasonic vibration on cutting force and cutting temperature decrease. There are adverse effects on surface roughness after ultrasonic vibration superposition. The influence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

Ultrasonic Elliptical Vibration-Assisted Micro-Groove Turning

2014 ◽  
Vol 625 ◽  
pp. 603-606 ◽  
Author(s):  
Chen Zhang ◽  
Kornel Ehmann ◽  
Ying Guang Li ◽  
Ping Guo
Keyword(s):  
Cutting Forces ◽  
Burr Formation ◽  
Ultrasonic Frequency ◽  
Elliptical Vibration Cutting ◽  
Cutting Method ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Comparison Results ◽  
Series Of Experiments ◽  
Ultrasonic Elliptical Vibration

In ultrasonic vibration the cutting edge of a tool is vibrated in the principal or cutting direction, generally at a constant ultrasonic frequency. The main characteristic of this cutting method is its intermittent nature involving repeated cutting and pausing. In this paper, ultrasonic elliptical vibration cutting is used to assist micro-groove turning of cylindrical surfaces. The elliptical locus during the cutting process is generated by a newly designed 2D resonant ultrasonic vibrator. A series of experiments were performed to verify the effects of the ultrasonic elliptical vibrations. The generated cutting forces and burr formation were compared for the ordinary and the elliptical vibration-assisted cases. Comparison results show the effectiveness of the elliptical vibration cutting method in reducing cutting forces and alleviating burr formation.

The Study of Power Ultrasonic Vibration Cutting Heat

2011 ◽  
Vol 311-313 ◽  
pp. 297-300 ◽  
Author(s):  
Yan Jun Shao ◽  
Jian Qing Wang ◽  
X.J. Zhu ◽  
Quan Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Cutting Temperature ◽  
Maximum Temperature ◽  
Vibration Cutting ◽  
Average Temperature ◽  
Finite Element Software ◽  
Cutting Heat ◽  
Power Ultrasonic ◽  
Change Material ◽  
Ultrasonic Vibration Cutting

Cutting heat and the resulting temperature change material properties, thus it produces tremendous influence to cutting force, tool condition and surface roughness. The cutting heat generated by the power ultrasonic vibration cutting process were is calculated in this paper, the power ultrasonic vibration cutting is studied by using the finite element software, the conclusions are that during power ultrasonic vibration cutting, the cutting heat generated depends on the net cutting time of a vibration cycle, the rapid cooling is the main reason for lower cutting temperature in the separation stage of the workpiece and tool, and the maximum temperature of the tool is greater than conventional turning, but the average temperature of the tool is low than traditional turning.

A Study of Precision Sub-Dry Cutting Mechanism

2006 ◽  
Vol 315-316 ◽  
pp. 805-808 ◽  
Author(s):  
J.L. Ren ◽  
S. Lu ◽  
J.J. Ren ◽  
S.D. Gong
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Air Cooling ◽  
Cutting Mechanism ◽  
Dry Cutting ◽  
Cutting Method ◽  
Cutting Tool Wear

This paper analyzes the changes of cutting force, cutting temperature, and cutting-tool wear in the process of precision cutting. All these factors are considered in the test on GCr12, Cr12 and 45 steels. This test uses the sub-dry cutting method with green-air cooling and a little additive. Furthermore, it discusses the feasibility of sub-dry cutting on the basis of a comparison with other cutting methods

Study on the effect of semisolid lubricants on tribological properties of hardened steel during boring process

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Lawrance G. ◽  
P. Sam Paul ◽  
Varadarajan A.S.
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Tribological Properties ◽  
Cutting Temperature ◽  
Aluminium Oxide ◽  
Cutting Fluids ◽  
Tool Vibration ◽  
Content Type ◽  
Vibration Cutting ◽  
Cutting Zone

Purpose In the internal turning process, tool life and work piece quality are greatly influenced by the generation of heat in the cutting zone. During machining, cutting fluids are applied at the cutting zones to reduce heat generation and enhance tribological properties. However, in the boring process, cutting fluids cannot be applied at cutting zone properly, and wastage of cutting fluid is a threat to the ecology and personnel health. Hence, application of semisolid lubricant in the boring process is considered as an innovative technique for temperature reduction in cutting zone because of its eco-friendly system, which also has a higher ability of biodegradability. This paper aims to study the influence of semisolid lubricants comprising of grease,graphite, aluminium oxide in different composition applied at a tool–chip,tool–work interface using a semisolid lubricant applicator applied with varying pressure. Design/methodology/approach In the present study, the cutting performance during boring of AISI4340 steel is enhanced through the application of semisolid lubricant with different composition of grease, graphite and aluminium oxide applied at tool-work and tool-chip interface with varying pressure using semisolid lubricant applicator. Findings The results show that use of semisolid lubricant like grease, graphite and nano aluminium oxide at tool-chip interface with maximum pressure reduces cutting temperature, tool vibration, cutting force and surface roughness. Originality/value Reduce cutting temperature, tool vibration, cutting force and surface roughness.

Study on Cutting Force and Cutting Temperature of Coated Carbide Turning Inserts with 3D Chip-Breaker

2011 ◽  
Vol 314-316 ◽  
pp. 909-913 ◽  
Author(s):  
Yun He ◽  
Min Xiao ◽  
Hao Ni ◽  
Yi Chuan Bian ◽  
Min Wang
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Chip Breaker ◽  
Cutting Heat ◽  
Work Done ◽  
Coated Carbide

In this paper, four types P turning insert groove with 3D chip-breaker are investigated for the influence of cutting force, cutting temperature and chip deformation. The experimental result shows that cutting force and total cutting heat corresponding different insert type are not the same between each other. These experiments also show that the arrangement sequence of chips deformation is consistent with that of cutting temperature for four kind of turning insert. The greater chip deformation indicates more work done, thus the more cutting heat taken away.

Experimental Study on Prestressed Cutting of Alloy Ring Parts

2016 ◽  
Vol 836-837 ◽  
pp. 71-76
Author(s):  
Rui Tao Peng ◽  
Yang Ge Li ◽  
Xin Zi Tang ◽  
Zhuan Zhou
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Stress Distribution ◽  
Cutting Force ◽  
Surface Integrity ◽  
Compressive Residual Stress ◽  
Machining Process ◽  
Residual Tensile Stress ◽  
Machined Surface ◽  
Cutting Method

In order to solve the poor cutting performance for the titanium alloy and the serious residual tensile stress distribution on the machined surface in cutting titanium alloy, the utilization of prestressed cutting method is proposed to actively control the residual stress distribution status on the machined surface in machining process. Titanium alloy ring parts were pre-stretched at different condition by a lathe-specific pretension device respectively. By the cutting experimental, the cutting force ,chip formation and surface integrity indexes are compared and studied. The results show that in suitable compressive residual stress on machined surface are achieved by utilizing the prestressed cutting method ,meanwhile procedures of residual stress adjustment after machining could be omitted. Furthermore, the magnitude of compressive residual stress could be actively controlled by adjusting the magnitude of prestressed force in certain extent. And uniform saw-tooth chip are generated in prestressed cutting, meanwhile there’s no significant increment of cutting force. Prestressed cutting method could generate good surface integrity.

scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

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%.

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