The Simulation of the Influence of Honed Edge Radius on the Cutting Force and Torque in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 130-134 ◽  
pp. 1779-1784
Author(s):  
Tao Wang ◽  
Ya Shi Ke ◽  
Yi Dan Zhou
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Simulation Software ◽  
Cutting Edge ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the the cutting force and torque. According to the simulation, the z-axis force and torque increase while the margin of the fluctuation decrease with the honed edge radius increase. In this paper, the z-axis force and torque reach the maximum and the margin of fluctuation in the smallest when using the honed edge radius of 0.10mm.

The Simulation of the Influence of Honed Edge Radius on the Maximum Temperature in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 399-401 ◽  
pp. 1848-1851
Author(s):  
Yi Dan Zhou ◽  
Tao Wang
Keyword(s):  
Metal Cutting ◽  
Cutting Temperature ◽  
Simulation Software ◽  
Cutting Edge ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of 42CrMo with three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the maximum temperature of cutting area. According to the simulation, the maximum temperature does not absolutely increase with the honed edge radius increase. The cutting temperature reaches maximum when the honed edge radius is 0.06mm in this paper, meanwhile the margin of fluctuation in the smallest.

Drilling of bone: Effect of drill bit geometries on thermal osteonecrosis risk regions

2018 ◽  
Vol 233 (2) ◽  
pp. 207-218 ◽  
Author(s):  
Mohd Faizal Ali Akhbar ◽  
Ahmad Razlan Yusoff
Keyword(s):  
Ex Vivo ◽  
Helix Angle ◽  
Simulation Software ◽  
Drilling Process ◽  
Drill Bit ◽  
Temperature Elevation ◽  
Bone Drilling ◽  
Drilling Simulation ◽  
Deform 3D ◽  
Bone Effect

Bone-drilling operation necessitates an accurate and efficient surgical drill bit to minimize thermal damage to the bone. This article provides a methodology for predicting the bone temperature elevation during surgical bone drilling and to gain a better understanding on the influences of the point angle, helix angle and web thickness of the drill bit. The proposed approach utilized the normalized Cockroft–Latham damage criterion to predict material cracking in the drilling process. Drilling simulation software DEFORM-3D is used to approximate the bone temperature elevation corresponding to different drill bit geometries. To validate the simulation results, bone temperature elevations were evaluated by comparison with ex vivo bone-drilling process using bovine femurs. The computational results fit well with the ex vivo experiments with respect to different drill geometries. All the investigated drill bit geometries significantly affect bone temperature rise. It is discovered that the thermal osteonecrosis risk regions could be reduced with a point angle of 110° to 140°, a helix angle of 5° to 30° and a web thickness of 5% to 40%. The drilling simulation could accurately estimate the maximum bone temperature elevation for various surgical drill bit point angles, web thickness and helix angles. Looking into the future, this work will lead to the research and redesign of the optimum surgical drill bit to minimize thermal insult during bone-drilling surgeries.

Edge Forces in Metal Cutting: Fundamental Analysis and Experimental Verification

2020 ◽  
Author(s):  
Rimah S. Al Aridi ◽  
Ahmad M. R. Baydoun ◽  
Ramsey F. Hamade
Keyword(s):  
Experimental Verification ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Micro Machining ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Geometric Factors ◽  
Tool Cutting

Abstract In metal cutting, some of the generated forces do not contribute to chip formation. These forces are referred to as plowing forces and are induced mainly as result of the finite sharpness of the tool (cutting edge radius) and the tool’s land (flank). Determining the magnitude of these forces is essential to developing a better understanding of the mechanics and physics of applications that involve cutting at minimal feed values (e.g., micro-machining and vibration-assisted-micro-machining. It is well recognized that plowing forces increase with tool wear. This research estimates these forces by employing analytical and numerical simulations. An extensive experimental analysis is utilized to verify the simulated values of the plowing forces. The experimental verification is designed to measure these forces as a function of several cutting parameters. The developed methodology relates the plowing forces to geometric factors and process parameters such as cutting-edge radius, tool feed, and cutting speed.

Linear Sawing Apparatus and its Evaluation for Research Into High Speed Bone Sawing

2011 ◽  
Author(s):  
John J. Pearlman ◽  
Anil Saigal ◽  
Thomas P. James
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Material Behavior ◽  
Depth Of Cut ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Saw Blade

Previous research into the cutting mechanics of bone sawing has been primarily approached from the perspective of orthogonal metal machining with a single edge cutting tool. This was a natural progression from the larger body of knowledge on the mechanics of metal cutting. However, there are significant differences between typical orthogonal metal cutting parameters and those encountered in bone sawing, such as anisotropic material behavior, depth of cut on the order of cutting edge radius, chip formation mechanism in the context of a saw blade kerf, non-orthogonal considerations of set saw blade teeth, and cutting speed to name a few. In the present study, an attempt is made to overcome these shortcomings by employing a unique sawing fixture, developed to establish cutting speeds equivalent to those of typical sagittal saws used in orthopaedic procedures. The apparatus was developed for research into bone sawing mechanics and is not intended to be a commercial sawing machine. The sawing fixture incorporates the cutting speed possible with lathe operations, as well as the linear cutting capabilities of a milling machine. Depths of cut are on the same order of magnitude as the cutting edge radius typical to saw blade teeth. Initial measurements of cutting and thrust force, obtained with this new experimental equipment, are compared to previous work.

scholarly journals DRILL BIT SELECTION USING DESIGN OF EXPERIMENTS (DoE) METHOD

2020 ◽  
Vol 3 (01) ◽  
pp. 39-43
Author(s):  
Rieza Zulrian Aldio ◽  
Zainol Mustafa
Keyword(s):  
Metal Cutting ◽  
Critical Factor ◽  
Significance Test ◽  
Industrial Sector ◽  
Drilling Process ◽  
Drill Bit ◽  
Effect Analysis ◽  
Drill Point ◽  
Cutting Processes ◽  
Selection Of

Drilling process is one of the most common machning process in industrial sector. More than half of the metal-cutting processes are conducted by the drilling process. Drill bit has influenced the results of the drilling process. Therefore, selection of the suitable drill bit becomes a critical factor in the drilling process. This is because the use of the suitable drill bit could fulfill the determined specification value of the hole. Six Sigma and Failure Mode Effect Analysis (FMEA) methods are used to identify factors that have influenced the results of the drilling process. Then by using the Design of Experiment, selection of the best drill bit could be done. In this study, 2 factors that influenced the result are the drill bit type and the drill point angle. Significance test using nested design through MINITAB 14 application has shown that both factors have significant influence over the hole diameter size.. Then by using the plot from the MINITAB 14 application, HPMT 1 became the best drill bit because it could fulfill the specification value. As for the best point angle in this study is 139.72º. Process capability calculation of HPMT 1 has shown that the process is in control. The conclusion is that drill bit HPMT 1 with point angle 139.72º became the best option in this study.

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.

Lubrication Effect of Smeared Oil on Workpiece Surface in Intermittent Cutting With Very Short Cutting Duration

2020 ◽  
Author(s):  
Yoshiki Nakamura ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Satoru Maegawa ◽  
Xiaoxu Liu
Keyword(s):  
Cutting Force ◽  
Temperature Rise ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Frictional Heat ◽  
Low Viscosity ◽  
Ti Alloys ◽  
Intermittent Cutting

Abstract In the metal cutting, generally, application of lubricant to a cutting edge is one of the methods in order to suppress temperature rise of the cutting edge by reducing frictional heat. However, the reduction in friction with lubricant disappears at higher temperature environment because of the loss of lubricant oiliness associated with temperature rise. Conversely, this reduction effect might work only in the initial stage immediately after cutting edge /work engagement because the temperature is not so high. Therefore, if the cutting duration of each blade of end-mill is shorten by limiting the cutting length per once, the cutting temperature can be suppressed to be lower than the moderate magnitude for lubrication. On the other hand, Ti-alloys with low thermal conductivity would experience quite high temperature increase during the high-speed cutting process. Therefore, it is thought that lubricant cannot be used properly with conventional cutting methods. In this study, the high-speed milling method mentioned above was used to implement the machining of Ti-alloys, and the lubricant effects of different types oils were compared from two aspects as tool wear and cutting force. As a result, when using low-viscosity synthetic ester oil, the damage to the cutting edge was suppressed most. At the same time, there was no fluctuation in cutting force by repeated machining. From this result, it was suggested that the lubricant performance, in intermittent cutting with very short cutting duration, depends on the heat resistance and permeability of the oil.

Statistical Analysis of Cutting Force, Temperature and Power of FEM Modeling when Machining Titanium Alloy

2014 ◽  
Vol 693 ◽  
pp. 358-363 ◽  
Author(s):  
Ladislav Kandráč ◽  
Ildikó Maňková ◽  
Marek Vrabeľ ◽  
Jozef Beňo ◽  
Jozef Stahovec ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Cutting Edge ◽  
Fem Modeling ◽  
Cutting Edge Radius ◽  
Edge Radius

FEM analysis was performed on design of experiment (DoE) according to Taguchi plan L9 (34). In order to overcome the machinability issues associated with machining of Ti-6Al-4V alloy, an attempt has been made in this study to observe the effect of friction coefficient, cutting speed, feed rate and cutting edge radius and on cutting force, temperature and power in 2D orthogonal cutting process supported through out with Third Wave Systems’ AdvantEdge. The comparison between the predicted cutting force, temperature and power at varying of friction coefficient, cutting speed, feed rate and cutting edge radius are presented and discussed. Evaluation of obtained results was processed by the statistical software Minitab 16.

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