scholarly journals FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3789
Author(s):  
Michele Lanzetta ◽  
Marco Picchi Picchi Scardaoni ◽  
Armin Gharibi ◽  
Claudia Vivaldi
Keyword(s):  
Material Properties ◽  
Analytical Modeling ◽  
Cutting Tool ◽  
Sustainable Manufacturing ◽  
Cutting Parameters ◽  
Micro Machining ◽  
Machining Processes ◽  
Steel Alloys ◽  
Diamond Blade ◽  
Micro Features

This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes.

A novel approach to machining process fault detection using unsupervised learning

2020 ◽  
pp. 095440542093755
Author(s):  
Thomas McLeay ◽  
Michael S Turner ◽  
Keith Worden
Keyword(s):  
Fault Detection ◽  
Unsupervised Learning ◽  
Tool Path ◽  
Cutting Tool ◽  
Novelty Detection ◽  
Cutting Parameters ◽  
Machining Process ◽  
Machining Processes ◽  
Workpiece Material ◽  
Data Set

The most common machining processes of turning, drilling, milling and grinding concern the removal of material from a workpiece using a cutting tool. The performance of machining processes depends on a number of key method parameters, including cutting tool, workpiece material, machine configuration, fixturing, cutting parameters and tool path trajectory. The large number of possible configurations can make it difficult to implement fault detection systems without having to train the system to a particular method or fault type. The research of this article applies a novel method to detect the changing state of a process over time in order to detect faulty machining conditions such as worn tools and cutting depth changes. Unlike studies in the previous literature in this domain, an unsupervised learning method is used, so that the method can be applied in production to unfamiliar processes or fault conditions. In the case presented, novelty detection is applied to a multivariate sensor feature data set obtained from a milling process. Sensor modalities include acoustic emission, vibration and spindle power and time and frequency domain features are employed. The Mahalanobis squared-distance is used to measure discordancy of each new data point, and values that exceed a principled novelty threshold are categorised as fault conditions.

Study on Nylon Cutting Properties Based on Cutting Temperature with Material Properties in Manufacturing System

2012 ◽  
Vol 252 ◽  
pp. 319-322 ◽  
Author(s):  
Ning Fan ◽  
Pei Quan Guo ◽  
Xiu Li Fu
Keyword(s):  
Finite Element Method ◽  
Material Properties ◽  
Manufacturing System ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Workpiece Surface ◽  
Key Factor ◽  
On Chip

In nylon material manufacturing process, cutting temperature is key factor to nylon cutting properties. The glass transition temperature should be regarded as criteria for determining proper cutting parameters. The cutting temperatures variation of workpiece and chip with time under different rake angles are calculated by finite element method. It is shown that cutting temperature on workpiece surface is higher than that on chip and decreases quickly. The rake angle of cutting tool has great effects on workpiece cutting temperature. Thus the rake angle should be rationally selected to guarantee quality for manufacturing system.

Cutting Tool Condition Monitoring in Machining Processes - A Comprehensive Approach Using ANN Based Multisensor Fusion Strategy

2012 ◽  
Vol 232 ◽  
pp. 966-972
Author(s):  
Abderrazak El Ouafi ◽  
Michel Guillot ◽  
Noureddine Barka
Keyword(s):  
Condition Monitoring ◽  
Cutting Tool ◽  
Cutting Parameters ◽  
Tool Condition Monitoring ◽  
Comprehensive Approach ◽  
Cnc Machine Tools ◽  
Multisensor Fusion ◽  
Machining Processes ◽  
Fusion Strategy ◽  
Tool Condition

On-line cutting tool condition monitoring becomes one of the most critical requirements in machining processes for improving the efficiency and the autonomy of CNC machine tools. The processes can be significantly improved by using an intelligent integration of sensor information to detect and identify accurately the tool condition under various cutting parameters. This paper presents a structured and comprehensive approach for tool condition monitoring in machining processes using ANN based multisensor fusion strategy. Various sensing techniques are combined to select suitable monitoring indices and several models are proposed to establish the relationship between tool condition and the selected monitoring indices. The proposed approach is built progressively by examining monitoring indices from various aspects and making monitoring decision step by step. The results indicate a significant improvement and a good reliability in identifying various tool conditions regardless of the variation in cutting parameters.

scholarly journals Influence of Tool Path Strategies and Pocket Geometry on Surface Roughness in Pocket Milling

2020 ◽  
Vol 9 (2) ◽  
pp. 884-888
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
Cutting Tool ◽  
Cutting Parameters ◽  
Milling Process ◽  
End Mill ◽  
Roughness Measurement ◽  
Machining Processes ◽  
Pocket Milling ◽  
Carbide Insert

This paper discusses the effect of tool path strategies and pocket geometry to surface roughness due to pocket milling process. The machining processes have been performed on mould steel DF2 using carbide insert end mill as the cutting tool. The cutting parameters for this experiment were kept constant while the variables were cutting tool, path strategies and pocket geometries at three levels each. The effectiveness of different tool path strategy and different pocket geometry is evaluated in terms of measured surface roughness (Ra) of the workpiece. The grade of a pocket is directly proportional with its surface roughness. The lowest surface roughness measurement was produced by pocket geometry B with parallel spiral cutting tool path strategy.

scholarly journals CAD-Based Automated Design of FEA-Ready Cutting Tools

2020 ◽  
Vol 4 (4) ◽  
pp. 104
Author(s):  
Anastasios Tzotzis ◽  
César García-Hernández ◽  
José-Luis Huertas-Talón ◽  
Panagiotis Kyratsis
Keyword(s):  
Computer Aided Design ◽  
Cutting Tool ◽  
Parametric Design ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Automated Design ◽  
Three Dimensions ◽  
Machining Processes ◽  
Element Analysis ◽  
Cad System

The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.

Assessment of Machining Cost for End-Milling of Ti-6Al-4V Titanium Alloy through RSM-Based Parametric Model

2014 ◽  
Vol 903 ◽  
pp. 83-89
Author(s):  
A.N. Mustafizul Karim ◽  
M. Ikram ◽  
H.M. Emrul Kays ◽  
M. Abdesselam ◽  
T.L. Ginta
Keyword(s):  
Titanium Alloy ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Technical Solution ◽  
Machining Processes ◽  
Tool Insert ◽  
The Cost ◽  
Cutting Tool Insert

Past few decades have been marked by significant achievements in the development of cutting tools and machining processes. End-milling operation with Polycrystalline Diamond (PCD) cutting tool insert presents a good technical solution for machining difficult-to-cut materials. However, the cost of each technical or technological solution is a major concern in the decision making process. It is quite common for a solution developer to encounter a question like How much will this new method cost? before proceeding for implementation. PCD insert applied as a cutting tool is a recent development and evaluation of economic performance of this cutting tool insert in end-milling of a-difficult-to-cut material such as Ti-6Al-4V titanium alloy can be of significant importance to the manufacturer. However, cost economy depends significantly on the correct choice of cutting conditions especially in the context of cutting parameters. To determine the economically desired levels of the cutting parameters for PCD insert to end-mill Titanium alloy we have presented a RSM-based mathematical model which would help to estimate the cost of removing unit volume of material and to find out the optimum cutting conditions leading to minimum machining cost.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

A Bi-Directional Ultrasonic Elliptical Vibration Actuator (BUEVA) for Micro Machining

2009 ◽  
Author(s):  
Ali H. Ammouri ◽  
Ramsey F. Hamade
Keyword(s):  
Tool Path ◽  
Cutting Parameters ◽  
Micro Machining ◽  
Tool Positioning ◽  
Elliptical Vibration ◽  
Machining Center ◽  
Precise Tool ◽  
Multilayer Actuator ◽  
Tool Motion ◽  
Ultrasonic Elliptical Vibration

Presented is the detailed design and implementation of a bi-directional ultrasonic elliptical vibration actuator (BUEVA) for micro machining. Removal of material occurs via a generated elliptical tool motion resembling a natural ‘spoon feeding’ action in contrast to in-plane, horizontal motion utilized by most existing setups. The motion is generated by two stacked ceramic multilayer actuator ring (SCMAR) piezo elements vibrating out of phase in the tool’s axial and transverse directions. The amplitude of vibration of the tool is controlled in order to vary the cutting depth according to the desired cutting parameters. To ensure precise tool positioning, the BUEVA actuator is fitted to a 3-axis precision machining center that provides the necessary tool path. The cutting forces and the resulting surface finish are both numerically modeled and then experimentally measured by a 3-axis mini dynamometer and a surface profilometer, respectively. Preliminary cutting results show good dimensional definition and surface integrity.

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