Reserch on Cutting Depth Effect in Cutting Process

2011 ◽  
Vol 128-129 ◽  
pp. 251-254
Author(s):  
Zhao Wei Dong ◽  
Xiao Hang Wan ◽  
Shu Jun Li ◽  
Sheng Yong Liu
Keyword(s):  
Residual Stress ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Fem Analysis ◽  
Work Piece ◽  
Cutting Depth ◽  
Depth Effect ◽  
Chip Breaking ◽  
The Status ◽  
Cutting Model

In the cutting procedure, the cutting depth influences cutting forces, chip breaking, chip shaping, and the distribution status of residual stress. The two-dimension heat-mechanic coupling orthogonal cutting model is established with the FEM analysis software by use of the Lagrange quality point coordinate system description method in this paper. This paper simulates a typical work-piece chip breaking process with different cutting depth, which gets the cutting forces curves and the total status of residual stress distribution and the status.

Simulation and Analysis of Cutting Tools Corner Radius in Cutting Process

2010 ◽  
Vol 42 ◽  
pp. 114-117
Author(s):  
Zhao Wei Dong ◽  
Xiao Hang Wan ◽  
Sheng Yong Liu
Keyword(s):  
Residual Stress ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Process ◽  
Work Piece ◽  
Adaptive Meshing ◽  
Chip Breaking ◽  
Corner Radius ◽  
The Status

In the procedure of cutting, its corner radius influences cutting forces, chip breaking, chip shaping, and the distribution status of residual stress. The author adopts the Finite Element Method (FEM) in this paper, and establishes the reasonable two-dimension milling model based on the orthogonal cutting process, which is used the adaptive meshing criteria. And, a typical work-piece chip breaking process with different cutting tools corner radius, which gets the cutting forces curves and the total status of residual stress distribution and the status is simulated in this paper.

FEM Analysis of Residual Stress Distribution and Cutting Forces in Orthogonal Cutting with Different Initial Stresses

2014 ◽  
Vol 800-801 ◽  
pp. 380-384 ◽  
Author(s):  
Yuan Ma ◽  
Ding Wen Yu ◽  
Ping Fa Feng
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Compressive Stress ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Cutting Parameters ◽  
Initial Stresses

Machining induced residual stress is influenced by many factors. Extensive studies on the influence of cutting parameters, tool parameters, as well as basic properties of materials have been carried out during the past decades, while another important factor, initial stress distribution in workpiece, was often ignored. In this paper a relatively complete FEM simulation on the formation mechanism of machining induced residual stress in high speed machining is carried out, illustrating the three stress zones affected by mechanical and thermal loads, and their influence on ultimate residual stress. And the influence of initial compressive stress on stress formation and cutting forces is analyzed. Initial compressive stress weakens the tensile effect caused by the shear deformation, and the residual stress tend to be more compressive with larger initial compressive stress. Cutting force becomes larger with the increase of initial compressive stress. And the results in this FEM study can be used to explain some unaccounted experimental phenomena in former researches.

The Simulation Analysis of Tool Orthogonal Rakes Affecting Metal Cutting

2011 ◽  
Vol 128-129 ◽  
pp. 1277-1280
Author(s):  
Xiao Hang Wan ◽  
Zhao Wei Dong ◽  
Shu Jun Li ◽  
Sheng Yong Liu
Keyword(s):  
Metal Cutting ◽  
Simulation Analysis ◽  
Orthogonal Cutting ◽  
Fem Analysis ◽  
Work Piece ◽  
Adaptive Meshing ◽  
Analysis Software ◽  
Cutting Mechanism ◽  
Technical Parameters ◽  
Cutting Model

Adopted the theory of elastic-plastic deformation, used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the adaptive meshing criteria and simulates a typical work-piece chip breaking process. This paper simulates different tool orthogonal rakes how affect the cutting process, which is very significant in engineering. This paper supplies the theory foundation of optimizing the technical parameters and deeply studying the cutting mechanism.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

An Eulerian Orthogonal Cutting Model for Unidirectional Fiber-Reinforced Polymers

2018 ◽  
Vol 140 (2) ◽  
Author(s):  
Shengqi Zhang ◽  
John S. Strenkowski
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Damage Model ◽  
Subsurface Damage ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Unidirectional Fiber ◽  
Frp Composites ◽  
Cutting Model

An Eulerian model is described that simulates orthogonal cutting of unidirectional fiber-reinforced polymer (FRP) composites. The continuous finite element method (FEM) and the discontinuous Galerkin (DG) method are combined to solve the governing equations. A progressive damage model is implemented to predict subsurface damage in the composite. A correction factor that accounts for fiber curvature is included in the model that incorporates the influence of fiber bending. It was found that fiber orientation has a dominant influence on both the cutting forces and subsurface damage. Good agreement was found between predicted cutting forces and subsurface damage and published experimental observations.

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.

Modeling and Experiment of the Cutting Force for Aluminium Alloy Work-Piece

2012 ◽  
Vol 268-270 ◽  
pp. 422-425
Author(s):  
Mu Lan Wang ◽  
Jun Ming Hou ◽  
Bao Sheng Wang ◽  
Wen Zheng Ding
Keyword(s):  
Finite Element ◽  
Aluminium Alloy ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Experimental Period ◽  
Production Costs ◽  
Work Piece ◽  
Force Model ◽  
Oblique Cutting ◽  
Cutting Model

The application of Finite Element Method (FEM) in cutting force model for Aluminium alloy work-piece is useful to reduce the production costs and shorten the experimental period. Firstly, the theoretical model of the orthogonal cutting and the oblique cutting are analyzed in this paper. And then, the corresponding finite element models are theoretically constructed. By comparing the results, the following conclusions are drawn: with the increase of the cutting thickness, the cutting force increasing is in an enhancement tendency. The oblique cutting model of overall tool is more conductive to the subsequent runout and the flutter analysis.

Analysis of Cutting Forces in Precision Turning Based on Oblique Cutting Model

2010 ◽  
Vol 97-101 ◽  
pp. 1961-1964 ◽  
Author(s):  
Wei Guo Wu ◽  
Gui Cheng Wang ◽  
Chun Gen Shen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Differential Method ◽  
Force Model ◽  
Cutting Force Model ◽  
Linear Change ◽  
Oblique Cutting ◽  
Precision Turning ◽  
Cutting Model

In this work, the prediction and analysis of cutting forces in precision turning operations is presented. The model of cutting forces is based on the oblique cutting force model which was rebuilt by two coordinate conversions from the orthogonal cutting model. Then the cutting field in precision turning was divided into two fields which are characterized as curve change and linear change on cutter edge and they were modeled respectively. Cutting field of cutter nose was modeled by differential method and its cutting force distribution is predicted by the proposed method. The predicted results for the cutting forces are in agreement with the experimental results under a variety of operation variables, including changes in the depths of cut and in the feedrate.

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.

The Simulation Analysis of Friction Effect on Cutting Process

2011 ◽  
Vol 314-316 ◽  
pp. 1065-1068
Author(s):  
Shu Jun Li ◽  
Xiao Hang Wan ◽  
Zhao Wei Dong ◽  
Yuan Yuan
Keyword(s):  
Friction Coefficient ◽  
Coulomb Friction ◽  
Simulation Analysis ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Cutting Process ◽  
Machined Surface ◽  
System Description ◽  
Cutting Model

Adopted the Lagrange quality point coordinate system description method used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the ameliorated Coulomb friction theory to simulate the friction status between the chips and tools. This paper simulates the cutting process with different friction coefficient. It can draw conclusions that the cutting forces and the residual stresses of machined surface are increasing with the raising of touching length of rake face and chip, the raising of cutting temperature. The friction coefficient has the important effect on the machining quality.

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