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.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

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 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.

FE analysis of the effects of process representations on the prediction of residual stresses and chip morphology in the down-milling of Ti6Al4V

2021 ◽  
pp. 1-40
Author(s):  
Nejah Tounsi ◽  
Tahany El-Wardany
Keyword(s):  
Residual Stresses ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Milling Process ◽  
Cutting Edge ◽  
Uncut Chip Thickness ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract In part II of these two-part papers, the effects of four FEM representations of the milling process on the prediction of chip morphology and residual stresses (RS) are investigated. Part II focuses on the milling of conventional uncut chip thickness h with finite cutting edge radius and flank wear, while part I of these two-part papers has reported on the results in the case of milling small uncut chip thickness in the micrometre range with finite cutting edge radius. Two geometric models of the flank-wear land composed of flat and curved wear land are proposed and assessed. The four process representations are: i) orthogonal cutting with flat wear land and with the mean uncut chip thickness h ¯; ii) orthogonal cutting with flat wear land and with variable h, which characterises the down-milling process and which is imposed on a flat surface of the final workpiece; iii) modelling the true kinematics of the down milling process with flat wear land and iv) modelling the true kinematics of the down milling process with curved wear land. They are designated as Cte-h, Var-h, True-h and True-h*. The effectiveness of these representations is assessed when milling Ti6Al4V with a flank-wear land of VB = 200µm.

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.  

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