Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses. This was obtained by exploring various magnitudes of the shear friction factor and heat transfer coefficient and choosing proper coefficients using the calibration of the predicted results with the measured ones. The experimental results showed that the effect of cutting environment including dry and flood-coolant modes was negligible on machining forces. The experimental investigation also demonstrated that increasing feed rate raised machining forces, tool wear and residual stresses in both cutting environments. Low Speed Cutting (LSC) led to the highest value of tool wear and High Speed Cutting (HSC) provided the lowest values of resultant machining forces and residual stresses in both modes. Flood-coolant mode reduced tool wear and slightly decreased tensile residual stresses in comparison with dry mode. As a result, low feed rate and high-speed cutting under flood-coolant mode were proposed in order to improve tool wear and residual stress in orthogonal cutting of AA6061-T6.

Download Full-text

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.315-316.140 ◽

2006 ◽

Vol 315-316 ◽

pp. 140-144 ◽

Cited By ~ 1

Author(s):

Su Yu Wang ◽

Xing Ai ◽

Jun Zhao ◽

Z.J. Lv

Keyword(s):

Residual Stress ◽

Finite Element ◽

Surface Layer ◽

Residual Stresses ◽

High Speed ◽

Metal Cutting ◽

Orthogonal Cutting ◽

High Speed Machining ◽

Machined Surface ◽

Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Download Full-text

Tool Wear Mechanisms in High Speed Machining Ductile Cast Iron

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.29-32.1527 ◽

2010 ◽

Vol 29-32 ◽

pp. 1527-1531

Author(s):

Fa Zhan Yang ◽

Jian Qiang Zhou ◽

Guang Yao Meng ◽

Jun Zhao ◽

Chang He Li

Keyword(s):

Cast Iron ◽

Tool Wear ◽

Tool Life ◽

High Speed ◽

Wear Behavior ◽

Orthogonal Cutting ◽

Ductile Cast Iron ◽

Cemented Carbide ◽

Rake Face ◽

High Speed Cutting

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

Download Full-text

Effect Residual Stress on Material Hardness by Finite Element Simulation during the Process of High Speed Cutting

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.719.23 ◽

2016 ◽

Vol 719 ◽

pp. 23-27

Author(s):

De Weng Tang ◽

Zhi Feng He ◽

Xi Jian Lv ◽

Cong Peng

Keyword(s):

Residual Stress ◽

Finite Element ◽

Residual Stresses ◽

High Speed ◽

Cutting Temperature ◽

Element Model ◽

Residual Tensile Stress ◽

Machined Surface ◽

High Speed Cutting ◽

Material Hardness

Residual stresses induced during the process of high speed cutting are very critical due to safety and corrosion resistance. Based on the nonlinear finite element code DEFORM, thermodynamic couple model of residual stress was built. Effect distribution of residual stresses on three different materials physical properties of hardness are analyzed by using the finite element model during the process of high speed cutting. The results show that metal material hardness is the key factors to residual stress. When materials’ hardness is higher, residual tensile stress is easy to form on the machined surface due to high cutting temperature, such as hardened steel SKD11(HRC=62). To lower hardness material, residual compressive stress is generated on the machined surface for plastic deformation, such as softer materials 7075Al (HRC=23).

Download Full-text

Study on Residual Stress in High-Speed Cutting NAK80 Mold-Steel

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.217-219.458 ◽

2012 ◽

Vol 217-219 ◽

pp. 458-462

Author(s):

Jian Xin Pan ◽

Zhi Xiong Zhou

Keyword(s):

Residual Stress ◽

Finite Element ◽

High Speed ◽

Orthogonal Cutting ◽

Tool Geometry ◽

Stress Distributions ◽

High Speed Cutting ◽

Finite Element Software ◽

Cutting Model ◽

Cutting Speeds

An orthogonal cutting model was presented，and the cutting process was simulated by a finite element software based on the thermal-elastic-plastic FEM theory and updated Lagrange method.We obtained the distributions of residual stresses in machined layer of NAK80 mold-steel.The effects of cutting speeds，cutting depths and tool geometry on residual stress distributions were investigated. Comparing to experimental results，the conclusions are more accurate.

Download Full-text

Surface Roughness and Residual Stresses of High Speed Turning 300 M Ultrahigh Strength Steel

Advances in Mechanical Engineering ◽

10.1155/2014/859207 ◽

2014 ◽

Vol 6 ◽

pp. 859207 ◽

Cited By ~ 2

Author(s):

Zhang Huiping ◽

Zhang Hongxia ◽

Lai Yinan

Keyword(s):

Residual Stress ◽

Surface Roughness ◽

Prediction Model ◽

Feed Rate ◽

High Speed ◽

Stress Test ◽

Orthogonal Cutting ◽

Cutting Speed ◽

Depth Of Cut ◽

Factors Affecting

Firstly, a single factor test of the surface roughness about tuning 300 M steel is done. According to the test results, it is direct to find the sequence of various factors affecting the surface roughness. Secondly, the orthogonal cutting experiment is carried out from which the primary and secondary influence factors affecting surface roughness are obtained: feed rate and corner radius are the main factors affecting surface roughness. The more the feed rate, the greater the surface roughness. In a certain cutting speed rang, the surface roughness is smaller. The influence of depth of cut to the surface roughness is small. Thirdly, according to the results of the orthogonal experiment, the prediction model of surface roughness is established by using regressing analysis method. Using MatLab software, the prediction mode is optimized and the significance test of the optimized model is done. It showed that the prediction model matched the experiment results. Finally, the surface residual stress test of turning 300 M steel is done and the residual stress of the surface and along the depth direction is measured.

Download Full-text

The effect of process parameters and cutting tool shape on residual stress of SAE 52100 hard turned steel by high speed machining

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420929788 ◽

2020 ◽

Vol 235 (1-2) ◽

pp. 290-300 ◽

Cited By ~ 1

Author(s):

Nelson Wilson Paschoalinoto ◽

Ed Claudio Bordinassi ◽

Roberto Bortolussi ◽

Fabrizio Leonardi ◽

Sergio Delijaicov

Keyword(s):

Residual Stress ◽

Residual Stresses ◽

Process Parameters ◽

Feed Rate ◽

High Speed ◽

Cutting Speed ◽

Cutting Parameters ◽

Cutting Depth ◽

Tool Shape ◽

Factorial Design Of Experiments

This study focused on determining the residual stress of SAE 52100 hard-turned steel. The objective was to evaluate and compare the effects of the cutting-edge geometry and cutting parameters (cutting speed, feed rate, and cutting depth) on the residual stresses of three different conventional inserts: S-WNGA08 0408S01020A 7025, T-WNGA08 0408T01020A 7025, and S-WNGA432S0330A 7025. Tests were performed on 60 samples of SAE 52100 hardened steel with an average hardness of 58.5 HRC. The circumferential residual stresses of the samples were measured by X-ray diffraction. A full factorial design of experiments with three factors and two levels each with two central points and a replicate was used for a statistical analysis. The most significant results were as follows: For all inserts, the measured residual stresses were compressive, which extended the tool lifespan. The residual stresses of the Type-S inserts were significantly influenced by the cutting speed and depth, and those of the Type-T insert were significantly influenced by the feed rate and cutting depth. In addition, the residual stresses of the insert 3 were more compressive than those of the other two types of inserts. In other words, residual stresses are more compressive for inserts with larger chamfer angles even as the principal residual stress profiles were all compressive. This work has also shown that it is possible to determine a significant statistical relationship between cutting forces and residual stresses, allowing force measurements to predict the residual stress without any information on process parameters.

Download Full-text

Residual stresses in thermite welded rails: significance of additional forging

Welding in the World ◽

10.1007/s40194-020-00912-4 ◽

2020 ◽

Vol 64 (7) ◽

pp. 1195-1212

Author(s):

B. Lennart Josefson ◽

R. Bisschop ◽

M. Messaadi ◽

J. Hantusch

Keyword(s):

Residual Stress ◽

Stress Field ◽

Residual Stresses ◽

Weld Metal ◽

Welding Process ◽

Surface Zone ◽

Fe Model ◽

Uneven Surface ◽

Residual Stress Field ◽

High Dynamic

Abstract The aluminothermic welding (ATW) process is the most commonly used welding process for welding rails (track) in the field. The large amount of weld metal added in the ATW process may result in a wide uneven surface zone on the rail head, which may, in rare cases, lead to irregularities in wear and plastic deformation due to high dynamic wheel-rail forces as wheels pass. The present paper studies the introduction of additional forging to the ATW process, intended to reduce the width of the zone affected by the heat input, while not creating a more detrimental residual stress field. Simulations using a novel thermo-mechanical FE model of the ATW process show that addition of a forging pressure leads to a somewhat smaller width of the zone affected by heat. This is also found in a metallurgical examination, showing that this zone (weld metal and heat-affected zone) is fully pearlitic. Only marginal differences are found in the residual stress field when additional forging is applied. In both cases, large tensile residual stresses are found in the rail web at the weld. Additional forging may increase the risk of hot cracking due to an increase in plastic strains within the welded area.

Download Full-text

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

Jurnal Teknologi ◽

10.11113/jt.v78.9158 ◽

2016 ◽

Vol 78 (6-9) ◽

Cited By ~ 4

Author(s):

Mohd Shahfizal Ruslan ◽

Kamal Othman ◽

Jaharah A.Ghani ◽

Mohd Shahir Kassim ◽

Che Hassan Che Haron

Keyword(s):

Surface Roughness ◽

Magnesium Alloy ◽

Feed Rate ◽

High Speed ◽

Cutting Parameters ◽

Experimental Result ◽

Depth Of Cut ◽

Polishing Process ◽

High Speed Cutting ◽

Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

Download Full-text

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.557-559.1364 ◽

2012 ◽

Vol 557-559 ◽

pp. 1364-1368

Author(s):

Yong Feng ◽

Mu Lan Wang ◽

Bao Sheng Wang ◽

Jun Ming Hou

Keyword(s):

Temperature Distribution ◽

High Speed ◽

Metal Cutting ◽

Constitutive Relations ◽

Orthogonal Cutting ◽

Cutting Speed ◽

Fe Model ◽

Process Variables ◽

Machined Surface ◽

Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

Download Full-text