Detektion von Schneidkantenversatz und Rautiefe/Surface quality and cutting edge offset detection

2021 ◽  
Vol 111 (11-12) ◽  
pp. 803-806
Author(s):  
Dominik Hasselder ◽  
Eckart Uhlmann
Keyword(s):  
Tool Wear ◽  
Austenitic Steel ◽  
Surface Topography ◽  
Surface Quality ◽  
Academic Research ◽  
Cutting Edge ◽  
Geometrical Parameters ◽  
Dry Turning ◽  
Nominal Diameter

Bei Drehbearbeitung auftretender Verschleiß am Werkzeug ist seit Jahrzehnten Gegenstand der Forschung, denn er beeinflusst die Oberflächengüte und den resultierenden Durchmesser des Werkstücks. Durch die gezielte Platzierung eines Triangulationssensors lassen sich Einflüsse dieser Art detektieren. In Zerspanungsuntersuchungen bei der Bearbeitung des austenitischen Stahls 1.4301 ohne Kühlmedium konnte gezeigt werden, dass der verschleißbedingte Durchmesserfehler und die hergestellte Oberflächentopografie prozesssicher messbar sind.   Tool wear and its detection has been part of academic research for decades. It may result in varying surface quality and is a potential cause of insufficient nominal diameter in turning. Mounting a triangulation laser on a turning tool allows for detecting variations in geometrical parameters of the workpiece. Also, when dry turning the austenitic steel 1.4301 it is possible to continuously detect the resulting surface topography and the discrepancy in the manufactured diameter.

scholarly journals Research on Cutting Performance in High-speed Milling of TC11 Titanium Alloy Using Self-propelled Rotary Milling Cutters

2021 ◽  
Author(s):  
Yujiang Lu ◽  
Tao Chen
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
Wear Mechanism ◽  
High Speed ◽  
Cutting Edge ◽  
Machining Process ◽  
High Speed Milling ◽  
Tc11 Titanium Alloy ◽  
Milling Forces

Abstract Titanium alloy materials, with excellent chemical and physical properties, are widely applied to the manufacture of key components in the aerospace industry. Nevertheless, its hard-to-machine characteristic causes various problems in the machining process, such as severe tool wear, difficulty to ensure good surface quality, etc. To achieve high efficiency and quality of machining titanium alloy materials, this paper conducted an experimental research on the high-speed milling of TC11 titanium alloy with self-propelled rotary milling cutters. In the work, the wear mechanism of self-propelled rotary milling cutters was explored, the influence of milling velocity was analyzed on the cutting process, and the variation laws were obtained of milling forces, chip morphology and machined surface quality with the milling length. The results showed that in the early and middle stages of milling, the insert coating peeled off evenly under the joint action of abrasive and adhesive wear mechanisms. As the milling length increased, the dense notches occurred on the cutting edge of the cutter, the wear mechanism converted gradually into fatigue wear, and furthermore coating started peeling off the cutting edge with the occurrence of thermal fatigue cracks on the insert. As the milling length was further extended, the milling forces tended to intensify, the chip deformation worsened, and the obvious cracks occurred at the bottom of chips. Moreover, the rise in milling velocity reduced the tool wear resistance, increased obviously the milling forces and the surface roughness.

Investigation of surface topography and its deterioration resulting from tool wear evolution when dry turning of titanium alloy Ti-6Al-4V

2019 ◽  
Vol 135 ◽  
pp. 130-142 ◽  
Author(s):  
Xiaoliang Liang ◽  
Zhanqiang Liu ◽  
Gonghou Yao ◽  
Bing Wang ◽  
Xiaoping Ren
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Topography ◽  
Dry Turning

scholarly journals Statistical modeling, Sobol sensitivity analysis and optimization of single-tip tool geometrical parameters in the cortical bone machining process

2019 ◽  
Vol 234 (1) ◽  
pp. 28-38 ◽  
Author(s):  
Vahid Tahmasbi ◽  
Mehdi Safari ◽  
Jalal Joudaki
Keyword(s):  
Sensitivity Analysis ◽  
Cortical Bone ◽  
Surface Quality ◽  
Rake Angle ◽  
Cutting Edge ◽  
Numerical Control ◽  
Geometrical Parameters ◽  
Machining Parameters ◽  
Edge Angle ◽  
Input Parameters

Machining and cutting of cortical bones are very common and important in the field of orthopedic surgeries. Considerable advances in bone machining are obtained by using computer numerical control machines and automatic surgery robots but still, researches are needed to investigate the effects of machining parameters in bone machining. In this article, for the first time, the effect of geometrical parameters of the single-tip tool on cortical bone machining is studied. The machining parameters included in the investigation are rake angle, back rake angle and side cutting edge angle and the response surface methodology is used to analyze the obtained surface quality according to a second-order regression model. The sensitivity of surface quality to the input parameters was measured by applying Sobol sensitivity analysis and the results are optimized by the Derringer algorithm. Finally, the optimum tool is determined as 15° rake angle, −5° back rake angle and 30° side cutting edge angle. Furthermore, the sensitivity of the surface quality to the input parameters is determined as 52% for rake angle, 31% for side cutting edge angle and 17% for back rake angle.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

Study on Feed Offset in Elliptical Vibration Cutting

2014 ◽  
Vol 490-491 ◽  
pp. 600-606
Author(s):  
Jie Qiong Lin ◽  
Jin Guo Han ◽  
Dan Jing ◽  
Xian Jing
Keyword(s):  
Surface Topography ◽  
Surface Quality ◽  
Simulation Analysis ◽  
Three Dimensional ◽  
Curved Surface ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Tool Edge

Elliptical vibration cutting (EVC) process and three dimensional cutting surfaces are analyzed in this paper to understand the formation of surface topography. The model of EVC surface topography is established based on curved surface remove function under the assumption that the tool edge is sharp enough. And simulation analysis of surface topography is conducted with different feed offset ratios. Results indicate that RMS change with feed offset ratios λ. The range of RMS is larger when feed offset ratio ranges from both 0 to 0.4 and 0.6 to 1, while the range is smaller when feed offset ratio changes from 0.4 to 0.6. Whats more, RMS reaches the minimum when feed offset ratio is 0.5. The present research provides some references for reducing the height of vibration ripples and improving EVC surface quality.

scholarly journals The Comparative Study on Cutting Performance of Different-Structure Milling Cutters in Machining CFRP

2018 ◽  
Vol 8 (8) ◽  
pp. 1353
Author(s):  
Tao Chen ◽  
Fei Gao ◽  
Suyan Li ◽  
Xianli Liu
Keyword(s):  
Carbon Fiber ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Edge ◽  
Cutting Performance ◽  
Machining Process ◽  
Carbon Fiber Composites ◽  
Machined Surface ◽  
Milling Cutter ◽  
Machined Surface Quality

Carbon fiber reinforced plastic (CFRP) is typically hard to process, because it is easy for it to generate processing damage such as burrs, tears, delamination, and so on in the machining process. Consequently, this restricts its wide spread application. This paper conducted a comparative experiment on the cutting performance of the two different-structure milling cutters, with a helical staggered edge and a rhombic edge, in milling carbon fiber composites; analyzed the wear morphologies of the two cutting tools; and thus acquired the effect of the tool structure on the machined surface quality and cutting force. The results indicated that in the whole cutting, the rhombic milling cutter with a segmented cutting edge showed better wear resistance and a more stable machined surface quality. It was not until a large area of coating shedding occurred, along with chip clogging, that the surface quality decreased significantly. At the stage of coating wear, the helical staggered milling cutter with an alternately arranged continuous cutting edge showed better machined surface quality, but when the coating fell off, its machined surface quality began to reveal damage such as groove, tear, and fiber pullout. Meanwhile, burrs occurred at the edge and the cutting force obviously increased. By contrast, for the rhombic milling cutter, both the surface roughness and cutting force increased relatively slowly.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

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