scholarly journals Cutting Forces and Chip Shaping When Finish Turning of 17-4 PH Stainless Steel under Dry, Wet, and MQL Machining Conditions

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1187
Author(s):  
Kamil Leksycki ◽  
Eugene Feldshtein ◽  
Joanna Lisowicz ◽  
Roman Chudy ◽  
Roland Mrugalski
Keyword(s):  
Stainless Steel ◽  
Cutting Force ◽  
Cutting Forces ◽  
Experimental Studies ◽  
Fem Simulation ◽  
Depth Of Cut ◽  
Finish Turning ◽  
Cooling Conditions ◽  
Chip Shape ◽  
Feed Force

This paper analyses three components of total cutting force and chip shape changes when finish turning 17-4 PH (precipitation hardening) stainless steel. A Finite Element Method (FEM) simulation of cutting forces was also performed using the Johnson–Cook constitutive model. The results were compared with those obtained from experimental studies. Variable feeds of 0.05–0.4 mm/rev and depth of cut of 0.2–1.2 mm with a cutting speed of 220 m/min were used. The studies were carried out under dry and wet cooling conditions and with the use of minimum quantity lubrication (MQL). This research was realized based on the Parameter Space Investigation (PSI) method. Statistical analysis of the obtained results was carried out using Statistica-13 software. It was found that the cutting force Fc and feed force Ff depend on the depth of cut and feed, and the passive force Fp depends mainly on the feed. Compared to dry cutting conditions, a reduction of 43% and 39% of the cutting force Fc was achieved for wet machining and MQL machining, respectively. Regardless of the cooling conditions, a favorable chip shape was registered for ap = 1–1.1 mm and f = 0.25–0.3 mm/rev. Compared to the experimental studies, the FEM simulation showed differences of ~13% for the cutting force Fc and of ~36% for the feed force Ff.

scholarly journals Determination of Energy Consumption during Turning of Hardened Stainless Steel Using Resultant Cutting Force

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 565
Author(s):  
Rusdi Nur ◽  
Noordin Mohd Yusof ◽  
Izman Sudin ◽  
Fethma M. Nor ◽  
Denni Kurniawan
Keyword(s):  
Stainless Steel ◽  
Energy Consumption ◽  
Cutting Force ◽  
Cutting Forces ◽  
Electrical Energy ◽  
Machining Process ◽  
Depth Of Cut ◽  
Electrical Energy Consumption ◽  
Nose Radius ◽  
Finish Turning

Downsizing energy consumption during the machining of metals is vital for sustainable manufacturing. As a prerequisite, energy consumption should be determined, through direct or indirect measurement. The manufacturing process of interest is the finish turning which has been explored to generate (near) net shapes, particularly for hardened steels. In this paper, we propose using measured cutting forces to calculate the electrical energy consumption during the finish turning process of metals where typically the depth of cut is lower than the cutting tool nose radius. In this approach, the resultant cutting force should be used for calculating the energy consumption, instead of only the main (tangential) cutting force as used in the conventional approach. A case study was carried out where a hardened stainless steel (AISI 420, hardness of 47–48 HRC) was turned using a coated carbide tool, with a nose radius of 0.8 mm, without cutting fluid, and at 0.4 mm depth of cut. The experimental design varied the cutting speed (100, 130, and 170 m/min) and feed (0.10, 0.125, and 0.16 mm) while other parameters were kept constant. The results indicate that the electrical energy consumption during the particular dry turning of hardened steel can be calculated using cutting force data as proposed. This generally means machining studies that measure cutting forces can also present energy consumption during the finish or hard turning of metals, without specifically measuring the power consumption of the machining process. For this particular dry turning of hardened stainless steel, cutting parameters optimization in terms of machining responses (i.e., low surface roughness, long tool life, low cutting force, and low energy consumption) was also determined to provide an insight on how energy consumption can be integrated with other machining responses towards sustainable machining process of metals.

Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness of Quartz Glass

2013 ◽  
Vol 641-642 ◽  
pp. 367-370
Author(s):  
Gui Qiang Liang ◽  
Fei Fei Zhao
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Diamond Wheel ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Feed Force

Abstract In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force and cutting force) and surface roughness in milling of Quartz glas using diamond wheel. The cutting process in the up-cut milling of glass is discussed and the cutting force measured. The cutting force gradually increases with the cutter rotation at the beginning of the cut, and oscillates about a constant mean value after a certain undeformed chip thickness. The results show that cutting forces and surface roughness do not vary much with experimental cutting speed in the range of 55–93 m/min. The suggested models of cutting forces and surface roughness and adequately map within the limits of the cutting parameters considered.

ANALYSIS OF CUTTING FORCES WHILE TURNING DIFFERENT MATERIAL

2020 ◽  
Vol 15 (4) ◽  
Author(s):  
Krishna Kumar M ◽  
Sangaravadivel P
Keyword(s):  
Cutting Force ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Tool Material ◽  
Radial Force ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Force

The measurement of cutting forces in metal cutting is essential to estimate the power requirements, to design the cutting tool and to analyze machining process for different work and tool material combination. Although cutting forces can be measured by different methods, the measurement of cutting forces by a suitable dynamometer is widely used in industrial practice. Mechanical and strain gauge dynamometer are most widely used for measuring forces in metal cutting. The principle of all dynamometers is based on the measurement of deflections or strain produced from the dynamometer structure from the action of cutting force. In this project, a dynamometer is used to measure cutting force, feed force and radial force by using strain gauge accelerometer while turning different material in lathe. The dynamometer is a 500kg force 3- component system. As the tool comes in contact with the work piece the various forces developed are captured and transformed into numerical form system. In this project three forces of different materials such as aluminum, mild steel, brass, copper have been noted down. The forces on these materials with variation in speed and depth of cut are studied. Graphs are drawn on how these forces vary due to variation in speed.

Modeling and Analysis of Cutting Forces in Hard Turning T250 Steel Using CBN Tools

2010 ◽  
Vol 154-155 ◽  
pp. 694-700
Author(s):  
Yue Ding ◽  
Xi Bin Wang ◽  
Li Jing Xie ◽  
Hao Yang
Keyword(s):  
Cutting Force ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Cutting Forces ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Modeling And Analysis ◽  
Feed Force

The objective of this paper is to study the cutting forces in hard turning T250 steel with CBN tools. Experiments based on the Box-Behnken design were conducted to develop the cutting forces models by response surface methodology (RSM). Significance tests of the model are performed by the analysis of variance (ANOVA). It is also discussed the effects of cutting parameters (cutting speed, feed rate and depth of cut) on the cutting force components. The results show that the models can fit experimental data via analysis of variance. The most important cutting parameter is depth of cut, followed by feed rate, while the effect of cutting speed can be neglected. Compared to cutting force and feed force, thrust force is the largest. In addition, the cutting forces generated by the uncoated tool are smaller than by the coated one due to tool wear.

Experimental Investigation of Effect of the Laser-Assisted Finish Turning of Ti-6Al-4V Alloy on Machinability Indicators

2017 ◽  
Vol 261 ◽  
pp. 135-142 ◽  
Author(s):  
Witold F. Habrat
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Laser Power ◽  
Laser Scanning ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Finish Turning ◽  
Laser Assisted Machining ◽  
Melted Zone

In this paper, the experimental studies of the finish turning of Ti-6Al-4V titanium alloy with the laser-assisted machining were described. For the tests, a cemented carbide tool was used. The influence of the laser heating on the microstructure of Ti-6Al-4V titanium alloy for kinematics corresponding with the turning process was determined. For a laser scanning rate of 80 m/min and laser power 1200W, the maximum depth of the melted zone was about 50 μm. The beneficial effect of laser assisted machining on components of the cutting force was established. For a cutting speed of 80 m/min, feed rate 0.1 mm/rev, depth of cut 0.25 mm and laser power 1200 W, over 60% reduction of the tangential components of cutting force was observed. The chip-breaking effect for the conventional and the laser-assisted processes was determined. Roughness parameters of the surface after the conventional and laser-assisted turning are compared.

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%.

Experimental study and multi-objective optimization of process parameters during turning of 100Cr6 using C-type advanced coated tools

2021 ◽  
pp. 095440622110431
Author(s):  
LR Bhandarkar ◽  
PP Mohanty ◽  
SK Sarangi
Keyword(s):  
Cutting Force ◽  
Distance Measure ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
X Ray ◽  
Coated Tools ◽  
Reduction Coefficient ◽  
Machining Parameter

The drive of this research is to examine the machinability of 100Cr6 bearing steel using advanced C-type cutting tools. Experimental studies investigated the effects of machining variables on the surface quality, chip reduction coefficient and cutting force. Seven advanced coated tools were checked for characterization by micro hardness (VHN), adhesion quality, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDXS). The experimental trials were planned by Taguchi’s L18 orthogonal array using a mixed-level design. Two numerical machining variables feed rate and cutting speed, and one categorical machining variable tool type was taken into consideration while a constant depth of cut was kept for all trails. A combined Taguchi-Satisfaction function distance measure approach was implemented for multi-response optimization. The most promising machining parameter setting for minimization of surface roughness, cutting force, and chip reduction coefficient was identified. The most important process parameter was found to be tool-type. Ceramics tools are found to be best trailed by WC coated tools under most of the conditions. Lower tool wear was observed in the CBN tool as compared to others.

FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

Experimental study on cutting force in ultrasonic vibration-assisted turning of 304 austenitic stainless steel

2020 ◽  
pp. 095440542095712
Author(s):  
Yingshuai Xu ◽  
Zhihui Wan ◽  
Ping Zou ◽  
Weili Huang ◽  
Guoqing Zhang
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Relational Model ◽  
Depth Of Cut ◽  
Technological Parameters ◽  
High Efficient ◽  
304 Austenitic Stainless Steel

The generation mechanism of cutting force in ultrasonic vibration assisted turning (UAT), with the composition and decomposition of cutting force is discussed in this paper, and the model of cutting force in UAT is established based on the mechanism of UAT. The force measuring test system is designed on the basis of the established machining system of UAT. The contrast experiments for turning the workpiece of 304 austenitic stainless steel are conducted with and without ultrasonic vibration under different technological parameters. Furthermore, the relational model and correlation between technological parameters and cutting force is obtained by regression analysis and variance analysis. Thereby, the mutual relation among these technological parameters is effectively controlled, which contributes to achieving the high quality and high efficient processing. Simultaneously, the influences of single technological parameter with the interaction between technological parameters on cutting force are researched and analyzed. The results prove that the cutting force is reduced significantly with the aid of ultrasonic vibration in turning and the choice of the proper ultrasonic amplitude, there is an optimal range of ultrasonic amplitudes as well. Meanwhile, the cutting parameters have great influence on cutting force, among which depth of cut has the superior influence, then the cutting speed, and feed rate has the minimal influence. Moreover, cutting parameters should not be too large, UAT is mainly used for semi-finishing or finishing at medium-low speed. UAT will get more ideal machining effect if cutting parameters are chosen properly.

An AI-Based Model for Predicting Instananeous Cutting Force in End Milling

Manufacturing ◽  
2002 ◽  
Author(s):  
Hazim El-Mounayri ◽  
Vipul Tandon
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Ann Model ◽  
Force Signal ◽  
Input Variables ◽  
Artificial Neural Network Ann

An Artificial Neural Network (ANN) model is developed to accurately predict the instantaneous cutting forces in flat end milling. A unique frequency domain approach is presented and is seen to simulate instantaneous cutting forces reasonably well. A set of eight input variables is chosen to represent the machining conditions and frequency domain parameters of the cutting force signal are generated. Three input parameters are varied, namely Feed, Speed and Depth of Cut. Four output parameters are suggested as a sufficient set to adequately reproduce the instantaneous cutting forces. Exhaustive experimentation is conducted to collect data (consisting of Fx, Fy, and Fz) to train and validate the model.

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