scholarly journals Predictive Analytical Modeling of Thermo-Mechanical Effects in Orthogonal Machining

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7876
Author(s):  
Alliche Mohamed-Amine ◽  
Djennane Mohamed ◽  
Djebara Abdelhakim ◽  
Songmene Victor
Keyword(s):  
Empirical Model ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Temperature Prediction ◽  
Dust Emissions ◽  
Dust Generation ◽  
Orthogonal Machining

Factor relationships in a machining system do not work in pairs. Varying the cutting parameters, materials machined, or volumes produced will influence many machining characteristics. For this reason, we are attempting to better understand the effect of the Johnson-Cook (J-C) law of behavior on cutting temperature prediction. Thus, the objective of the present study is to investigate, experimentally and theoretically, the tool/material interactions and their effects on dust emission during orthogonal cutting. The proposed approach is built on three steps. First, we established an experimental design to analyze, experimentally, the cutting conditions effects on the cutting temperature under dry condition. The empirical model which is based on the response surface methodology was used to generate a large amount of data depending on the machining conditions. Through this step, we were able to analyze the sensitivity of the cutting temperature to different cutting parameters. It was found that cutting speed, tool tip radius, rake angle, and the interaction between the cutting speed and the rake angle explain more than 84.66% of the cutting temperature variation. The cutting temperature will be considered as a reference to validate the analytical model. Hence, a temperature prediction model is important as a second step. The modeling of orthogonal machining using the J-C plasticity model showed a good correlation between the predicted cutting temperature and that obtained by the proposed empirical model. The calculated deviations for the different cutting conditions tested are relatively acceptable (with a less than 10% error). Finally, the established analytical model was then applied to the machining processes in order to optimize the cutting parameters and, at the same time, minimize the generated dust. The evaluation of the dust generation revealed that the dust emission is closely related to the variation of the cutting temperature. We also noticed that the dust generation can indicate different phenomena of fine and ultrafine particles generation during the cutting process, related to the heat source or temperature during orthogonal machining. Finally, the effective strategy to limit dust emissions at the source is to avoid the critical temperature zone. For this purpose, the two-sided values can be seen as combinations to limit dust emissions at the source.

scholarly journals Effect of Cutting Parameters on Cutting Temperature of TiAl6V4 Alloy

2013 ◽  
Vol 392 ◽  
pp. 68-72 ◽  
Author(s):  
S. Sulaiman ◽  
A. Roshan ◽  
S. Borazjani
Keyword(s):  
Feed Rate ◽  
Rate Increase ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Rake Angle ◽  
Coulomb’S Friction ◽  
Abaqus Software

A Finite Element Modeling (FEM) and Simulation was Used to Investigate the Effect of Tool Rake Angle, Cutting Speed and Feed Rate on the Cutting Temperature of Tial6v4 Alloy. the Purpose of this Study was to Find Proper Cutting Parameters for Machining of Titanium Alloy where Cutting Temperature was Lowest. A FEM Based on ABAQUS Software which Involves Jonson-Cook Material Model and Coulomb’s Friction Law was Applied to Simulate an Orthogonal Cutting Process. in this Simulation Work, a Range of Tool Rake Angle from 0° to 10°, a Range of Cutting Speed from 300 m/min to 600 m/min and a Range of Feed Rate between 0.1 Rev/mm and 0.25 Rev/mm were Investigated. the Simulation Results Indicated that Increase in Rake Angle Reduces Cutting Temperature while Increasing Cutting Speed and Feed Rate Increase the Cutting Temperature.

An Experimental Study of Orthogonal Cutting of SiCp/Al Composites: Cutting Forces Analysis

2012 ◽  
Vol 500 ◽  
pp. 230-235
Author(s):  
Shu Tao Huang ◽  
Li Zhou ◽  
Jin Lei Wang
Keyword(s):  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Mechanical And Thermal Properties ◽  
Cutting Depth ◽  
Metal Parts ◽  
Orthogonal Machining ◽  
Rapid Tool

Due to the superior mechanical and thermal properties of SiCp/Al composites, their poor machinability has been the main deterrent to their substitution for metal parts. Machining of SiCp/Al composites has been considerably difficult because the extremely abrasive nature of SiC reinforcements causes rapid tool wear. In this paper, an experiment was carried out to investigate the influence of the cutting speed, cutting depth and tool rake angle on cutting force during orthogonal machining of SiCp/Al composites. The results indicate that the cutting depth is one of the main cutting parameters that affect the cutting force, while the cutting speed and tool rake angle have no significant effects on the cutting force.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

Cutting Force Empirical Model of High-Speed Precision Hard Cutting GCr15

2009 ◽  
Vol 69-70 ◽  
pp. 301-305
Author(s):  
Jing Shu Hu ◽  
Yuan Sheng Zhai ◽  
Fu Gang Yan ◽  
Yu Fu Li ◽  
Xian Li Liu
Keyword(s):  
Cutting Force ◽  
Empirical Model ◽  
High Speed ◽  
Orthogonal Design ◽  
Cutting Speed ◽  
Least Square Method ◽  
Cutting Parameters ◽  
Least Square ◽  
Physical Parameters ◽  
Hard Cutting

In the cutting process, cutting force is one of the important physical parameters, which affects the generation of cutting heat, tool life and surface precision of workpiece directly. In this paper an orthogonal design of experiment and subsequent data is analyzed using high speed finish hard cutting GCr15 whose hardness is 65HRC. Cutting speed is 200-400m/min, to study the influence of cutting parameters on cutting force, cutting force empirical model has obtained from least square method.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Identification of Optimum Heating Temperature in Thermal Assisted Turning of Stainless Steel Using Three Different Approaches

2013 ◽  
Vol 393 ◽  
pp. 194-199 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Noor Hawa B. Mohamad Rasdi ◽  
Khairus Syakirah B. Mahmud ◽  
Abdul Hakam B. Ibrahim ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heating Temperature ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Work Piece ◽  
Optimum Temperature ◽  
Main Concept

Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Effects of cutting parameters on drilling performance of carbon black–reinforced polymer composite

2016 ◽  
Vol 232 (7) ◽  
pp. 1133-1142 ◽  
Author(s):  
Alper Uysal
Keyword(s):  
Surface Roughness ◽  
Composite Materials ◽  
Carbon Black ◽  
Polymer Composite ◽  
Experimental Studies ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Polymer Materials ◽  
Drill Point

Polymer composite materials can be produced by reinforcing carbon black, carbon fiber, graphite, graphene, metals and metal oxides, nanotubes, and so on. These types of composite materials can be employed in applications demanding electrical conductivity besides high specific strength and stiffness properties of polymer materials. In the literature, there is a lack of knowledge on the examination of drilling of particle-reinforced composite materials. In this study, drilling of pure polypropylene and carbon black–reinforced polypropylene composite material was investigated at different drill point angles, cutting speeds, and feeds. The cutting temperature of drill point and surface roughness of holes were examined. The experimental studies were designed by L27 full-factorial design, and analysis of variance statistical method was performed. According to the results, cutting temperature increased and surface roughness decreased with the increase in the cutting speed and feed and decrease in the drill point angle.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

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