scholarly journals An Investigation of the Adhesive Effect on the Flank Wear Properties of a WC/Co-based TiAlN-Coated Tool for Milling a Be/Cu Alloy

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 444
Author(s):  
Zuo ◽  
Lin ◽  
He
Keyword(s):  
Failure Process ◽  
Cutting Speed ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Processes ◽  
Tool Failure ◽  
Force Fluctuations ◽  
Adhesive Effect ◽  
The Impact ◽  
Peak Value

Abstract: In this paper, an experimental investigation, based on force special parameters, is adopted to analyze the relationship between the milling tool and adhesive phenomena in milling C17200. Generally speaking, the adhesive characteristics, force fluctuations, and tool failure are the main factors affecting the impact of the cutting process on tool wear patterns. However, difficult-to-cut materials, such as the beryllium–copper alloy C17200, require machining processes with tools with lives that are difficult to predict, due to their excellent mechanical properties. To analyze the tool failure process, a series of experiments based on cutting speed and tool geometry are presented in this paper to observe the adhesive effect on tool flank surfaces and force fluctuations. The results show that the variation of special force parameters in different directions reveals that the thermal–mechanical effect on sticking substances reached a possible peak value, with inflection points in different parameters at 200 m/min. The sticking substances and tool surfaces (observed by energy disperse spectroscopy and scanning electron microscope), wear capacity, and back-scattered electron imaging also confirmed that adhesion in the wear zone reached a peak value at 200 m/min in the cutting process, exacerbating the adhesive effect on tool failure.

Influence Analysis of Micro-Milling Vibrational Phenomena on Workpiece Topomorphy

2017 ◽  
Vol 261 ◽  
pp. 77-84 ◽  
Author(s):  
Evlampia Stergianni ◽  
Dimitrios Sagris ◽  
Christos Tsiafis ◽  
Constantine David ◽  
Ioannis Tsiafis
Keyword(s):  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Micro Milling ◽  
Formation Mechanisms ◽  
Force Measurements ◽  
Machining Processes ◽  
Metal Machining ◽  
On Chip ◽  
The Impact

In metal machining processes, it is necessary to study the vibration phenomena which take place in cutting area between the cutting tool and the workpiece in order to ascertain the factors that affect them. Subject of this paper is the analysis of the influence of vibration phenomena during micro-milling on chip formation mechanisms and thereby on the workpiece topomorphy. In particular, the cutting parameters, such as the cutting speed, the feed rate and the axial cutting depth, which affect the workpiece topomorphy are experimentally studied. Based on cutting force measurements correlated with the workpiece topomorphy under various cutting process parameters useful results are extracted. In this way, the impact of vibration phenomena, taking place in micro-milling due to the cutting process, on the workpiece topomorphy can be evaluated.

scholarly journals Machining force comparison for surface defect hard turning and conventional hard turning of AISI 52100 steel

2021 ◽  
Vol 13 (3) ◽  
pp. 205-214
Author(s):  
P. U MAMAHESWARRAO ◽  
D. RANGARAJU ◽  
K. N. S. SUMAN ◽  
B. RAVISANKAR
Keyword(s):  
Hard Turning ◽  
Surface Defect ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Machining Force ◽  
Aisi 52100 Steel ◽  
The Impact

In this article, a recently developed method called surface defect machining (SDM) for hard turning has been adopted and termed surface defect hard turning (SDHT). The main purpose of the present study was to explore the impact of cutting parameters like cutting speed, feed, depth of cut, and tool geometry parameters such as nose radius and negative rake angle of the machining force during surface defect hard turning (SDHT) of AISI 52100 steel in dry condition with Polycrystalline cubic boron nitride (PCBN) tool; and results were compared with conventional hard turning (CHT). Experimentation is devised and executed as per Central Composite Design (CCD) of Response Surface Methodology (RSM). Results reported that an average machining force was decreased by 22% for surface defect hard turning (SDHT) compared to conventional hard turning (CHT).

Machining Conditions Effect to Machining Temperature and Forces in Orthogonal Machining of Bone

2013 ◽  
Vol 658 ◽  
pp. 223-226 ◽  
Author(s):  
Denni Kurniawan ◽  
N. Jiawkok ◽  
M.Y. Noordin
Keyword(s):  
Analytical Study ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Allowable Limit ◽  
Machining Conditions ◽  
Orthogonal Machining ◽  
Dental Implantation ◽  
Cutting Direction

Bone machining processes are often performed in orthopaedic surgery and dental implantation, yet its analytical study is lacking. Towards contributing analysis on bone machining, this study reviews available references on orthogonal machining of bones. Considering the allowable limit in temperature and duration during bone machining to avoid thermal necrosis, machining temperature and forces are the machining responses of interest. Machining conditions (cutting speed, depth of cut, cooling method, tool geometry, and cutting direction) are analyzed in term of their effect to those machining responses.

Cutting Force Model for Heat Assisted Titanium Alloy Milling

2014 ◽  
Vol 887-888 ◽  
pp. 1191-1194 ◽  
Author(s):  
Chang Yi Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Shear Banding ◽  
Cutting Speed ◽  
Constitutive Law ◽  
Force Model ◽  
Machining Processes ◽  
Machine Material ◽  
The Impact

Thermal energy sources have been applied for softening the difficult-to-machine material when it is combined with conventional machining processes. Cutting forces has been reduced during the process. To investigate the plastic deformation property of workpiece materials heated by thermal sources, and its influence to the cutting forces, the analytical model of orthogonal cutting is established. The impact of cutting speed and initial temperature of the shear banding to the cutting forces are taken account of, based on adiabatic shear banding model and Johnson-Cook material constitutive law. The shear banding average shear stress failure criteria has been proposed to decide the fracture between workpiece and chip. Simulation has been carried out and compared with experimental data of laser-heat assisted titanium alloy milling, showing good agreement.

Analysis and Fabrication of a Mechanical Quick-Stop for Research on Chip Formation in Hard Turning Process

2019 ◽  
Vol 889 ◽  
pp. 87-94
Author(s):  
Nguyen Thi Quoc Dung
Keyword(s):  
Chip Formation ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
On Chip

Metal cutting is one of the most important machining processes in manufacturing industry. Thorough understanding of metal cutting process facilitates the optimization in selection of cutting tools and machining parameters. There are several methods used for studying phenomena in metal cutting process. Using a quick-top device is an efficient technique for investigation cutting process in which cutting action is stopped so suddenly that the “froze” specimen called the chip root honestly depicts what happened during cutting action. Design strategies of a quick-stop are accelerating cutting tool away from the workpiece or decelerating the workpiece remaining in engagement with the tool. Operation of a quick-stop device can be either mechanically or by explosive. Quick-stop devices can be utilized for various types of machining processes such as: turning, milling, drilling. This paper described the analysis, fabrication, and testing of a quick-stop device which is used for researching on chip formation in hard turning. This device has simple and safe operation which utilizes spring forces to retract the tool from workpiece during cutting. The results of performance at cutting speed of 283 m/min show that the separation distance is quite small, less than 0.2mm so that the deformations on the root chip are close to that while actual machining process. This indicates that the device has satisfied the requirements of an equipment for studying on chip formation.

scholarly journals Modeling of Cutting Parameters and Tool Geometry for Multi-Criteria Optimization of Surface Roughness and Vibration via Response Surface Methodology in Turning of AISI 5140 Steel

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4242 ◽  
Author(s):  
Mustafa Kuntoğlu ◽  
Abdullah Aslan ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
Tadeusz Mikolajczyk ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Prediction Models ◽  
High Reliability ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Tool Geometry ◽  
Machining Processes

AISI 5140 is a steel alloy used for manufacturing parts of medium speed and medium load such as gears and shafts mainly used in automotive applications. Parts made from AISI 5140 steel require machining processes such as turning and milling to achieve the final part shape. Limited research has been reported on the machining vibration and surface roughness during turning of AISI 5140 in the open literature. Therefore, the main aim of this paper is to conduct a systematic study to determine the optimum cutting conditions, analysis of vibration and surface roughness under different cutting speeds, feed rates and cutting edge angles using response surface methodology (RSM). Prediction models were developed and optimum turning parameters were obtained for averaged surface roughness (Ra) and three components of vibration (axial, radial and tangential) using RSM. The results demonstrated that the feed rate was the most affecting parameter in increasing the surface roughness (69.4%) and axial vibration (65.8%) while cutting edge angle and cutting speed were dominant on radial vibration (75.5%) and tangential vibration (64.7%), respectively. In order to obtain minimum vibration for all components and surface roughness, the optimum parameters were determined as Vc = 190 m/min, f = 0.06 mm/rev, κ = 60° with high reliability (composite desirability = 90.5%). A good agreement between predicted and measured values was obtained with the developed model to predict surface roughness and vibration during turning of AISI 5140 within a 10% error range.

A Study of the BTA Deep Drilling Process through a Quantitative and Qualitative Analysis of the Chip Formation Process

2013 ◽  
Vol 554-557 ◽  
pp. 1992-2008 ◽  
Author(s):  
Badis Haddag ◽  
Julien Thil ◽  
Mohammed Nouari ◽  
Claude Barlier
Keyword(s):  
Qualitative Analysis ◽  
Cutting Speed ◽  
Experimental Tests ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Hole Drilling ◽  
Physical Parameters ◽  
Drilling Process ◽  
The Impact ◽  
Optimal Cutting Parameters

This paper deals with the analysis of the cutting process in the BTA (Boring Trepanning Association) deep hole drilling. The process is a major technique of drilling when the machining with a conventional tool is not possible. Poor training and/or poor chips evacuation often cause a temperature rise and excessive wear detrimental to the tool life and the dimensional stability of machined parts. The process is relatively not explored enough, because it is difficult to instrument experimental tests (measurement of forces acting at each insert of the BTA drilling tool, temperature at each cutting edge…). Moreover, the thermomechanical phenomena related to the cut are localized at the end of the BTA drilling head and confined in a zone inaccessible to the observation. Hence, a study of this process based on a scientific approach has been proposed. The evaluation of the chips morphology has been performed. Indeed, it is a good indicator of the stability of the cutting process and it can therefore be a serious help in the selection of optimal cutting parameters. Adequate parameters are proposed to highlight the impact of cutting conditions on the cutting process. Macro and microscopic observations of generated chips under several cutting conditions are performed. Fragmentation and segmentation of chips are some examples of analysed phenomena. In this sense, experimental tests have been conducted. The chips have been sorted according to their morphology and identified according to their origin and then proposed physical parameters are assessed. The quantitative and qualitative analysis of chips allowed identifying the impact of the cutting speed and feed rate on the cutting process.

Experimental Investigation of Surface Roughness Using Uncoated and Coated Tungsten Carbide Cutting Tool in Turning Operation

2021 ◽  
Vol 39 (5A) ◽  
pp. 768-778
Author(s):  
Frzdaq N. Thamer ◽  
Ali A Khleif ◽  
Farhad M. Othman
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Substantial Effect ◽  
Cutting Process ◽  
Dry Cutting ◽  
The Impact

 The cutting process is an important process of industrialization. It is requisite to using advantage quality cutting tools in order to preserve the type of product. Coating on the cutting tool has a substantial effect in terms of mechanical properties and the end results of the product. The cutting tool can be manufactured in various material types, but today's cemented tungsten carbide is the most commonly used material in the tool industry because its properties comply with manufacturers' requirements. This study investigates the impact of an Al2O3 coated cutting tool relative to an uncoated cutting tool on the dry cutting process. Different parameters are used in the cutting process when cutting the metal. The cutting parameters used are feed rate and cutting speed, An analysis of the effects of these parameters on the surface roughness. In this analysis, the surface roughness are measured for components turned from steel1040, The L9 Taguchi orthogonal arrays and analyses of variance (ANOVA) was employed to analyze the influence of these parameters. In the case of (uncoated, Al2O3 coated tool), the better surface roughness (SR) with used feed rate (0.05 mm / rev) and cutting speed (140 m/min) where the roughness value was (0.81μm) and (0.78μm) Respectively. The results of this study indicate that the ideal parameters combination for the better surface finish was high cutting speed and low feed rate.

Research on Instantaneous Cutting Force of High Speed Ball-End Milling Cutter

2011 ◽  
Vol 188 ◽  
pp. 277-282 ◽  
Author(s):  
Chang Xing Qi ◽  
Bin Jiang ◽  
Min Li Zheng ◽  
Y.J. Yang ◽  
P. Sun
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Process ◽  
Energy Concentration ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Ball End Milling ◽  
The Impact

For the instability of ball-end milling cutter in high speed milling, instantaneous cutting process of high speed milling hardened steel was studied. The model of instantaneous cutting layer parameters of high speed ball-end cutter was established, and the influence of cutting speed and inclination angles on instantaneous cutting layer parameters were obtained. Using the model, instantaneous cutting force was studied, and high speed milling experiment was processed. Results show that the increase of cutting speed makes the change rate of cutting layer parameters increasing, leads to the energy concentration in cutting process, and increases the impact on milling cutter. The increase of inclination angle makes the instantaneous cutting layer parameters show a trend of decrease and the decrease of cutting thickness more rapidly, which caused instantaneous unit cutting force to increase and the instantaneous main cutting force appears increasing trend, and the cutting process become unstable.

Influence of cutting speed and tool geometry on form and machine tapping of carbon fibre-reinforced composites

2021 ◽  
Vol 43 (2) ◽  
Author(s):  
Sérgio Luiz Moni Ribeiro Filho ◽  
Túlio Hallak Panzera ◽  
Lincoln Cardoso Brandão ◽  
Alexandre Mendes Abrão
Keyword(s):  
Carbon Fibre ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Reinforced Composites ◽  
Fibre Reinforced Composites
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