Laser Assisted Micro-Groove Ball Milling of Ti6Al4V

2014 ◽  
Vol 660 ◽  
pp. 55-59 ◽  
Author(s):  
Zazuli Mohid ◽  
N.M. Warap ◽  
R. Ibrahim ◽  
E.A. Rhim
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ball Milling ◽  
Cutting Tool ◽  
Laser Source ◽  
Work Piece ◽  
Machining Performance ◽  
Machined Surface ◽  
Alloy Plate ◽  
Flank Surface

In micro scale, the size of cutting tool and shape significantly contributed to the machining performance. Many studies have been done to improve the cutting tool life and machined surface quality. Problems could become more severe when the workpiece has a low thermal conductivity while having high level of ductility such as titanium alloy. In this study, micro ball mill cutting tool is selected to produce a linear groove on a titanium alloy plate. The process is integrated with a laser source as a pre-heating element on the work piece surface. The condition of the flank surface of the tools and cutting force were observed and discussed. The influence of tool orientation and laser heating parameters in laser assisted micro ball milling (LAMM) were also discussed. It was found out that adhesion is the dominant tool wear mechanism thus fluctuate the cutting force value.

Performance evaluation of a tungsten carbide–based self-lubricant cutting tool

2016 ◽  
Vol 232 (10) ◽  
pp. 1825-1836 ◽  
Author(s):  
Ayyankalai Muthuraja ◽  
Selvaraj Senthilvelan
Keyword(s):  
Tungsten Carbide ◽  
Cutting Force ◽  
Tool Life ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Machined Surface ◽  
Flank Surface

Tungsten carbide cutting tools with and without solid lubricant (WC-10Co-5CaF2 and WC-10Co) were developed in-house via powder metallurgy. The developed cutting tools and a commercial WC-10Co cutting tool were used to machine cylindrical AISI 1020 steel material under dry conditions. The cutting force and average cutting tool temperature were continuously measured. The cutting tool flank surface and chip morphology after specific tool life (5 min of cutting) were examined to understand tool wear. The flank wear of the considered cutting tools was also measured to quantify the cutting tool life. The surface roughness of the workpiece was measured to determine the machining quality. The developed cutting tool with solid lubricant (WC-10Co-5CaF2) generated 20%–40% less cutting force compared to that of the developed cutting tool without solid lubricant (WC-10Co). In addition, the finish of the workpiece surface improved by 16%–20% when it was machined by the solid lubricant cutting tool. The cutting tool with solid lubricant (WC-10Co-5CaF2) exhibited a 15%–18% reduction in flank wear. Curlier and smaller saw tooth chips were generated from the WC-10Co-5CaF2 cutting tool, confirming that less heat was generated during the cutting process, and the finish of the machined surface was also improved.

Research on Cutting Force Spectrum Character and Tools Vibration Character under Titanium Alloy End-Surface Turning

2013 ◽  
Vol 274 ◽  
pp. 196-199
Author(s):  
Wei Zhang ◽  
Min Li Zheng ◽  
Ying Bin Li
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Parameters ◽  
Work Piece ◽  
Characteristic Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Testing Experiment ◽  
The Relationship

titanium alloy cutting force testing experiment of end-surface turning is made, and spectrum character is analyzed by obtained data of cutting force experiment, and ten the influencing rule of cutting parameter on cutting force character is discovered; using the similarity between tools vibration character and cutting force spectrum character, and based on obtained data of machined surface roughness testing experiment, the two characteristic parameters of vibration frequency and amplitude value relative to work piece is calculated, and the relationship curve between cutting parameters and tools vibration character parameter is established is this paper.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

An Investigation of Lateral Surface Hardness and Related Cutting Forces in One-Directional Ultrasonic-Vibration Assisted Turning

2012 ◽  
Vol 445 ◽  
pp. 1041-1046
Author(s):  
Hamed Razavi ◽  
Mohammad Javad Nategh ◽  
H. Soleimanimehr
Keyword(s):  
Cutting Force ◽  
Lateral Surface ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Tangential Direction ◽  
Feed Speed ◽  
Machined Surface ◽  
Average Force ◽  
Tool Edge

The experimental investigation of UAT shows that the movement of cutting tool edge relative to the workpiece results from the cutting speed, feed speed and tools vibration in tangential direction affects the lateral machined surface of workpiece and leaves a repeating pattern of toothed regions on it. In UAT process, because of constant feed rate of tool toward workpiece, the cutting tool never separates from workpiece, though the tool rake face may separate periodically from chip in every cycle of vibration. This results in an increase in the surface hardness of the lateral machined surface in comparison with conventional turning (CT). The results of the present study confirm the advantage of UAT as far as the lower cutting force is concerned compared with CT. The higher surface hardness of the lateral surface observed in UAT causes the maximum cutting force to increase but the average force decreases with respect to CT.

Strength of Cutting Tool in Titanium Alloy Machining

2016 ◽  
Vol 685 ◽  
pp. 427-431 ◽  
Author(s):  
Victor Kozlov ◽  
Jia Yu Zhang
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Contact Load ◽  
Internal Stresses ◽  
Compression Stress ◽  
Clearance Angle ◽  
Specific Contact

In this paper, contact conditions between cutting tool and work material, strength of cutting tool are analyzed. Experimental and theoretical studies of contact load distribution on the artificial flank wear-land that appears on the cutter in a free orthogonal turning disk of titanium alloy (Ti-6Al-2Mo-2Cr) are described. Calculations of internal stresses by the method of finite elements show that for the sharp cutter the main stresses into cutting wedge near to the cutting edge are compression stresses, very large (10 000 MPa) and exceed ultimate compression stress for cemented carbide. Decreasing of main stress with appearance of wear on the flank explains ability working of cutter even at large wear on the flank. Increasing of cutter’s break off probability with appearance of large wear on the flank is explained by increasing of zone where the internal stresses are large enough (more or equal 3 000 MPa) and increasing of defects probability into this zone, which serves as source of cracks. Abbreviation and symbols: m/s – meter per second (cutting speed v); mm/r – millimeter per revolution (feed rate f); MPa – mega Pascal (specific contact load as stress σ or τ); hf – the width of the flank wear land (chamfer) of the cutting tool, flank wear land can be natural or artificial like in this paper [mm]; xh – distance from the cutting edge on the surface of the flank wear land [mm]; σh – normal specific contact load on the flank land [MPa]; τh – shear (tangential) specific contact load on the flank land [MPa]; HSS – high speed steel (material of cutting tool); Py r – radial component of cutting force on the rake face [N]; Pz – tangential component of cutting force [N]; γ – rake angle of the cutting tool [°]; α – clearance angle of the sharp cutting tool [°]; αh – clearance angle of the flank wear land [°]; b – width of a machined plate or disk [mm]; σ-UTS - ultimate compression stress [MPa]; σUTS - ultimate tensile stress [MPa].

The Application of FEA in High-Speed Cutting Tool

2011 ◽  
Vol 314-316 ◽  
pp. 1258-1261
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Material Model ◽  
Friction Model ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools parameters are determined by simulating the influences of cutting temperature, cutting force on the tools parameters using FEA.

Calculation of Contact Stresses during Titanium Alloy Cutting

2018 ◽  
Vol 769 ◽  
pp. 364-370
Author(s):  
Victor Kozlov ◽  
Jia Yu Zhang ◽  
Ying Bin Guo ◽  
Sai Kiran Sabavath
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Cutting Tool ◽  
Contact Stresses ◽  
Cutting Edge ◽  
Initial Time ◽  
Small Magnitude ◽  
Normal Contact Stress ◽  
Normal Contact ◽  
Flank Surface

The paper presents data about distribution of contact stresses on a rake surface and flank-land of a cutter in free orthogonal turning of a disk made from a titanium alloy (Ti-6Al-2Mo-2Cr). On the cutting edge of the bar blade, there is a normal force Nρ, directed perpendicularly to a transient surface, with a large magnitude of specific linear force qN r= 182.6 N/mm, but the tangential force on the cutting edge Fρis equal to zero. On the rake surface, there are uniformly distributed shear contact stresses with very small magnitude of τ ≈ const ≈ 25 MPa, irrespective of feed rate, which speaks about plastic character of the contact on the rake surface. The greatest normal contact stress on the rake surface σmax≈ 1009 MPa, irrespective of feed rate. The greatest magnitude of normal contact stresses on the flank surface chamfer near the cutting edge σh max= 3400-2200 MPa confirms the hypothesis about recovery of a transient surface sag after separation of a formed element of a chip, and explains increased wear of the cutting tool on the flank surface at initial time. Normal σhand shear τhcontact stresses on the flank surface chamfer are essentially diminish with a distance from the cutting edge. It explains working ability of the cutting tool even at very large wear on the flank surface (hf> 3 mm). Our experimental data allows calculating the components of cutting force and contact stresses on the rake and flank surfaces of cutting tools during titanium alloy (Ti-6Al-2Mo-2Cr) machining.

Assessment of the Performance of Microbumped Cutting Tool in Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Contact Length ◽  
Machining Performance ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

scholarly journals Application of FEM in Investigating Machining Performance

2011 ◽  
Vol 264-265 ◽  
pp. 1033-1038
Author(s):  
Hendri Yanda ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Cast Iron ◽  
Cutting Force ◽  
Cutting Tool ◽  
Rake Angle ◽  
Ductile Cast Iron ◽  
Machining Performance ◽  
Stress Strain ◽  
Clearance Angle ◽  
Tool Geometries ◽  
Carbide Insert

The two biggest problems that often experienced in machining cast iron are poor machinability and high hardness. Up to now, many researchers have investigated machining performance and how to find optimum condition in machining ductile cast iron. This study aims to investigate the machining performance of ductile cast iron and carbide cutting tool using FEM. Performances were evaluated by changing the cutting tool geometries on the machining responses of cutting force, stress, strain, and generated temperature on the workpiece. Deform-3D commercial finite element software was used in this study. Ductile cast iron FCD 500 grade was used as the work piece material and carbide insert DNMA432 type with WC (Tungsten) was used for the cutting tool. The effects of rake and clearance angles were investigated by designing various tool geometries. Various combination of carbide insert geometries were designed using Solid Work to produce +15, +20 and +30 deg for rake angle and 5, 7, 8 and 9 deg for clearance angle. Machining condition for the simulations were remained constant at cutting speed of 200 m/min, feed rate of 0.35 mm/rev, and depth of cut of 0.3 mm. The results of effective-stress, strain and generated temperature on both chip and material surface were analysed. The results show that by increasing the rake angle (α), it will improves the machining performance by reducing the cutting force, stress, strain and generated temperature on surface of workpiece. But, by increasing the clearance angle (γ), it will not affect much to the cutting force, stress, strain and generated temperature on chip.

Research on the Influence of Tool Wear on Cutting Performance in High-Speed Milling of Difficult-to-Cut Materials

2016 ◽  
Vol 693 ◽  
pp. 1129-1134
Author(s):  
Zhao Ju Zhu ◽  
Jie Sun ◽  
Lai Xiao Lu
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Variation Trend ◽  
Cutting Tool Wear ◽  
Cutting Vibration

A series of research on the interactions among tool wear, cutting force and cutting vibration were conducted through high speed milling experiment in this paper, which objected the titanium alloy as difficult-to-cut materials. The results showed that the increasing of tool wear led to enlarging the cutting force and cutting vibration; and vice versa, the increasing of cutting force and cutting vibration aggravated the tool wear in the process of machining. Besides, the variation trend of tool wear with cutting was similar to the trend of cutting force, while the variation trend between cutting vibration and tool wear was different. Especially in the sharply cutting tool wear stage, the influence of tool wear on cutting vibration became more complicated.

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