scholarly journals Serrated Chips Formation in Micro Orthogonal Cutting of Ti6Al4V Alloys with Equiaxial and Martensitic Microstructures

Micromachines ◽  
2019 ◽  
Vol 10 (3) ◽  
pp. 197 ◽  
Author(s):  
ZeJia Zhao ◽  
Suet To ◽  
ZhuoXuan Zhuang
Keyword(s):  
Cutting Force ◽  
Unit Length ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Orthogonal Machining ◽  
Large Yield ◽  
Power Spectral ◽  
Straight Line ◽  
Serrated Chips ◽  
Electropulsing Treatment

The formation of serrated chips is an important feature during machining of difficult-to-cut materials, such as titanium alloy, nickel based alloy, and some steels. In this study, Ti6Al4V alloys with equiaxial and acicular martensitic microstructures were adopted to analyze the effects of material structures on the formation of serrated chips in straight line micro orthogonal machining. The martensitic alloy was obtained using highly efficient electropulsing treatment (EPT) followed by water quenching. The results showed that serrated chips could be formed on both Ti6Al4V alloys, however the chip features varied with material microstructures. The number of chip segments per unit length of the alloy with martensite was more than that of the equiaxial alloy due to poor ductility. Besides, the average cutting and thrust forces were about 8.41 and 4.53 N, respectively, for the equiaxed Ti6Al4V alloys, which were consistently lower than those with a martensitic structure. The high cutting force of martensitic alloy is because of the large yield stress required to overcome plastic deformation, and this force is also significantly affected by the orientations of the martensite. Power spectral density (PSD) analyses indicated that the characteristic frequency of cutting force variation of the equiaxed alloy ranged from 100 to 200 Hz, while it ranged from 200 to 400 Hz for workpieces with martensites, which was supposedly due to the formation of serrated chips during the machining process.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

scholarly journals Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5524
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Yongxiang Wu
Keyword(s):  
Simulation Model ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Interface Layer ◽  
Machining Process ◽  
Two Dimensional ◽  
Al Composite ◽  
The Matrix ◽  
Cutting Path

In this paper, a two-dimensional orthogonal cutting simulation model of SiCp/Al composite was established. The geometry and material constitutive model of the particle, the matrix, and the interface layer have been modeled respectively. In view of the distribution of the particles in the matrix, this paper proposed respectively a two-dimensional particle random distribution to simulate particles randomly distributed in the matrix. Then, the cutting state of SiC reinforced particles was analyzed, the novel approach was adopted the geometric shapes of SiC particles in this study is taken as an oval shape. Three different locations of SiC particle relative to the cutting tool path were simulated to analyze the cutting state such as particle removal. The interface layer was introduced to the case that the particle was on the cutting path to study the influence on the stress and strain transfer. Through the post-processing of simulation results, the influence of interface property on the composite reinforcement effect was studied quantificationally. Finally, the cutting process of SiCp/Al composite material was simulated. This paper studied the influence on the machined surface morphology, chip morphology, stress distribution, and cutting force of many factors of the cutting speed and the cutting thickness. The single factor orthogonal cutting experiment was designed the influence of cutting speed and feed rate on the cutting force. The cutting force results of the experiment and the simulation were compared through the deviation analysis, which verified the simulation model.

Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool

1998 ◽  
Vol 120 (1) ◽  
pp. 49-56 ◽  
Author(s):  
B. K. Ganapathy ◽  
I. S. Jawahir
Keyword(s):  
Cutting Force ◽  
Contact Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Two Dimensional ◽  
Cutting Force Model ◽  
Chip Breaking ◽  
Orthogonal Machining

The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes

2011 ◽  
Vol 223 ◽  
pp. 85-92 ◽  
Author(s):  
Balázs Tukora ◽  
Tibor Szalay
Keyword(s):  
Cutting Force ◽  
Real Time ◽  
Cutting Forces ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Work Piece ◽  
Processing Unit ◽  
Cutting Force Prediction ◽  
Force Prediction

In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

A Metallo-Thermo-Mechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of AISI 1045 steel based on a true metallo-thermo-mechanical coupled analysis. A metallo-thermo-mechanical coupled material model is developed, and a finite element model is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using ABAQUS. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7° to 5°. A good agreement is achieved in chip formation, cutting force and cutting temperature between the model predictions and the experimental data.

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 An Evaluation of Ploughing Models for Orthogonal Machining

1999 ◽  
Vol 121 (4) ◽  
pp. 550-558 ◽  
Author(s):  
D. J. Waldorf ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Cutting Tool ◽  
Metal Removal ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Machining Process ◽  
Separation Point ◽  
Workpiece Material ◽  
Orthogonal Machining ◽  
Edge Component ◽  
Material Separation

An analytical comparison is made between two basic models of the flow of workpiece material around the edge of an orthogonal cutting tool during steady-state metal removal. Each has been the basis for assumptions in previous studies which attempt to model the machining process, but no direct comparison had been made to determine which, if either, is an appropriate model. One model assumes that a separation point exists on the rounded cutting edge while the other includes a stable build-up adhered to the edge and assumes a separation point at the outer extreme of the build-up. Theories of elastic-plastic deformation are employed to develop force predictions based on each model, and experiments are performed on 6061-T6 aluminum alloy to evaluate modeling success. The experiments utilize unusually large cutting edge radii to isolate the edge component of the total cutting forces. Results suggest that a material separation point on the tool itself does not exist and that the model that includes a stable build-up works better to describe the experimental observations.

Finite Element Modelling of Orthogonal Cryogenic Machining Process

2016 ◽  
Vol 852 ◽  
pp. 248-254
Author(s):  
S. Sriram ◽  
V. Vignesh ◽  
K.S. Vijay Sekar ◽  
Murugasan Pradeep Kumar
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Modelling ◽  
Thrust Force ◽  
Machining Process ◽  
Maximum Temperature ◽  
Finite Element Models ◽  
Experimental Conditions ◽  
Element Modelling ◽  
Orthogonal Machining

The present work aims in creating the Finite Element Models for the conventional and the Cryogenic Orthogonal machining process. Finite Element Modelling (FEM) of the orthogonal machining operation was performed using DEFORM – 2D which is based on a modified Lagrangian formulation. Finite Element models were developed for various experimental conditions for both conventional and cryogenic orthogonal machining process. The response variables obtained from the models are cutting force, thrust force, temperature, shear stress, strain and strain rate. AISI 1045 steel is used as work material and for tool, tungsten carbide is used under various experimental conditions with the cutting speeds at 100 m/min, 150 m/min, 200 m/min and feeds at 0.07 mm/rev, 0.1 mm/rev, 0.14 mm/rev. A maximum temperature difference of 20.12% is obtained when conventional and cryogenic models were compared at a feed rate of 0.07 mm/rev and cutting speed of 150 m/min. cutting force and thrust force were higher for cryogenic model compared with that of the conventional model. Stress and Strain were distributed as expected to occur in the experiment.

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

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