A Finite Element Analysis of Micro/Meso-Scale Machining Considering the Cutting Edge Radius

2007 ◽  
Vol 10-12 ◽  
pp. 631-636 ◽  
Author(s):  
Zi Yang Cao ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Finite Element ◽  
Stress Field ◽  
Size Effect ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Process ◽  
Plastic Deformation Zone ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Meso Scale

In order to investigate the effects of cutting edge radius on micro/meso-scale cutting process, the current paper is concerned with a fundamental investigation of the contribution of cutting edge radius to cutting temperature, stress field and size effect by means of two-dimensional finite-element simulation for orthogonal cutting process. The results indicated that cutting edge radius has remarkable effects on cutting temperature and stress field, and the existence of cutting edge radius is one of the main reasons generating size effect. The cutting edge radius affects the micro/meso scale cutting process at smaller uncut chip thickness by altering the effective rake angle and enhancing the plowing effect, affecting the material deformation process, expanding and widening the plastic deformation zone, and causing higher energy dissipation due to increased tool-chip contact length.

Finite Element Analysis of the Influence of Cutting Edge Radius on Mechanical-Thermal Distribution in High-Speed Cutting TiAl6v4

2010 ◽  
Vol 458 ◽  
pp. 295-300
Author(s):  
Yi Hang Fan ◽  
Min Li Zheng ◽  
Shu Cai Yang ◽  
Wei Zhang ◽  
De Qiang Zhang
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Equivalent Stress ◽  
Cutting Edge ◽  
Plastic Deformation Zone ◽  
Edge Structure ◽  
High Speed Cutting ◽  
Cutting Edge Radius ◽  
Thermal Distribution ◽  
Edge Radius

On the basis of analyzing the cutting edge structure and cutting edge radius measurement of high-speed insert, thermal - mechanical coupling finite element method (FEM) is used in this paper, to obtain the effect law of different cutting edge radius on the mechanical-thermal distribution of high-speed cutting TiAl6V4. At last, cutting experiments are carried out to verify FEM results. There is a clear exposition of the intrinsic reason why the cutting edge radius has influence on the mechanical -thermal distribution of high-speed cutting process. The results indicate that the experimental results have a good agreement with FEM; with the cutting edge radius increases, cutting force increases; cutting temperature is not monotonic, but there exists an optimum edge radius that makes temperature lowest; cutting edge changes the plastic flow of materials around tool tip and broaden plastic deformation zone. The cutting edge radius has a greater impact on equivalent stress.

scholarly journals An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

Influences of Cutting Edge Radius on Cutting Deformation in High-Speed Machining Ti6Al4V

2011 ◽  
Vol 305 ◽  
pp. 47-52
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan ◽  
De Qiang Zhang ◽  
Ying Bin Li
Keyword(s):  
High Speed ◽  
Equivalent Stress ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Cutting Edge ◽  
High Speed Machining ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Cutting Deformation ◽  
Deformation Coefficient

In order to obtain the influences of cutting edge radius on cutting deformation in high-speed machining Ti6Al4V, cutting temperature, equivalent stress distribution, the chip morphology and cutting deformation coefficient were analyzed in this paper. The results indicated that cutting edge changed the plastic flow of materials around tool tip and the actual tool rake angle, the tool-workpiece and tool-chip contact in cutting process which causes a greater impact on physical and mechanical performance in the given cutting conditions. When the cutting edge radius reached to 0.04mm,the cutting temperature and the equivalent stress existed mutations, which causes the mutation of chips. There was a chip thinning effect with the increase of the cutting edge radius. As the cutting edge radius increased, chip thickness and shear angle decreased, cutting deformation coefficient increased.

scholarly journals Numerical Investigation on Effect of Rounded Cutting-Edge Radius and Machining Parameters in End Milling of AISI H13 Tool Steel

2018 ◽  
Vol 7 (4.30) ◽  
pp. 53
Author(s):  
Husni Nazra Abu Bakar ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Feed Rate ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Aisi H13

Rounded cutting-edge radius is commonly applied to finish and semi-finish cutting, precision machining and micro-machining. The optimum effect is closely related to the work and tool material as well as machining parameters. However, for numerous cutting process, the optimal radius of rounded cutting-edge radius and machining parameters applied in the AISI H13 of end-milling is yet unknown Therefore, in improving tool life and cutting tool performance, a suitable design of cutting edge geometry regarding cutting edge-radius and machining parameters need to be examined and properly selected. In this regard, the paper deals to examine the effect of cutting edge-radius in rounded form and machining parameters of cutting force, cutting temperature and chip formation through the end-milling process of AISI H13 using uncoated cemented carbide cutting tool through finite element simulation of Thirdwave AdvantEdge 7.2 software. The machining parameters applied in the simulation setup were 200 and 240m/min of cutting speed, 0.03 and 0.06mm/tooth of feed-rate and axial depth of cut of 0.1 and 0.2mm while width of cut in radial direction was kept constant at 6.0mm. The cutting geometries includes the cutting-edge radius of 0.03 and 0.05mm and 10° of rake angle. The obtained results revealed that cutting forces and cutting temperature is increase as depth of cut in axial direction and cutting-edge radius increases while increasing value of speed and feed-rate of cutting resulted in decreasing cutting forces but increasing cutting temperature. The maximum cutting temperature is 674.91℃. The value obtained is lesser than the AISI H13 austenitizing temperature, therefore a layer known as white layer is supposedly hard to be created based on the cutting geometry and machining parameters applied.  

Investigation of Size Effect on Micro Hardness of Machined Surface in Micro Cutting

2014 ◽  
Vol 602-605 ◽  
pp. 443-446
Author(s):  
Tao Zhang ◽  
Zhen Yu Shi ◽  
Bing Yan ◽  
Hou Jun Qi
Keyword(s):  
Size Effect ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Three Dimension ◽  
Micro Hardness ◽  
Uncut Chip Thickness ◽  
Machined Surface ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Edge Radius

Micro cutting is a promising way for manufacturing micro parts, especially micro three dimension parts. Micro hardness is an important character to evaluate surface integrity of machined surface. Micro cutting is different from macro cutting due to size effect of specific cutting energy because of the influence of the ratio of uncut chip thickness to cutting edge radius. A group of micro cutting experiments were conducted to investigate the cutting parameters on the micro hardness of machined surface. The micro hardness of machines surface decreases with the ratio of uncut chip thickness to cutting edge radius first, and then increase when the uncut chip thickness is smaller than the cutting edge radius. The micro hardness shows size effect due to the machined surface compressed twice with the round cutting edge. The micro hardness decreases with the distance increasing far away from the machined surface.

Finite Element Method Predicts the Distribution of Cutting Temperature in Diamond Turning

2007 ◽  
Vol 339 ◽  
pp. 100-105
Author(s):  
Wen Jun Zong ◽  
Dan Li ◽  
T. Sun ◽  
K. Cheng
Keyword(s):  
Temperature Field ◽  
Contact Area ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Diamond Turning ◽  
Cutting Edge ◽  
Fe Model ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Distribution Shape

In this paper, a coupled thermo-mechanical FE model is proposed to simulate the cutting temperature’s distribution produced in diamond turning. Simulated results indicate that the heat converting from plastic work has prominent effects on the distribution shape of cutting temperature field, and with an increment in cutting velocity, the locating site of maximal cutting temperature shifts from the contact area between tool tip and chip root to the contact area between rake face and chip. Cutting edge radius has minute influence on the distribution shape of cutting temperature field, but the bigger the cutting edge radius is, the higher the maximum cutting temperature in cutting region. Rake angle also has slight effects on the maximal temperature when it is more than 10○. While clearance angle reaches to 6○, the maximum cutting temperature approaches the smallest.

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