High-Speed Capturing of Stress Distribution of Workpiece under Ultrasonically Assisted Cutting Condition

2014 ◽  
Vol 1017 ◽  
pp. 747-752
Author(s):  
Hiromi Isobe ◽  
Keisuke Hara
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Light Emission ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Photoelastic Method ◽  
Intermittent Cutting ◽  
Ultrasonic Vibration Cutting

This paper reports the stress distribution inside the workpiece under ultrasonic vibration cutting (UVC) condition. Many researchers have reported the improvement of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVC condition. However general dynamometers have an insufficient frequency band to observe the processing phenomena caused by UVC. In this paper, stress distribution inside the workpiece during UVC was observed by combining the flash light emission synchronized with ultrasonically vibrating cutting tool and the photoelastic method. Instantaneous stress distribution during UVC condition was observed. Because UVC induced an intermittent cutting condition, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. It was found that instantaneous maximum cutting force during UVC condition was smaller than quasi-static cutting force during conventional cutting when the cutting speed was less than 500 mm/min.

High-Speed Capturing of Stress Distribution of Workpiece under Ultrasonically Assisted Cutting Condition

2016 ◽  
Vol 1136 ◽  
pp. 520-525
Author(s):  
Hiromi Isobe ◽  
Keisuke Hara
Keyword(s):  
Stress Distribution ◽  
Pulse Laser ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Condition ◽  
Ultrasonic Oscillation ◽  
The One ◽  
Intermittent Cutting ◽  
Ultrasonic Vibration Cutting ◽  
The Ideal

This paper reports the stress distribution inside the workpiece under ultrasonic vibration cutting (UVC) condition. Many researchers have reported the improvements of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVC condition. However general dynamometers have an insufficient frequency band to observe the ultrasonically varying processing phenomena induced by UVC. In this paper, stress distribution inside the workpiece was observed by combining the pulse laser as light source synchronized with ultrasonically vibrating cutting tool and the photoelastic method. The one shot of pulse laser with pulse width of 15nsec visualizes an instantaneous stress distribution. Sweeping the phase of emission against to ultrasonic oscillation, 360 frames for 35.7μs, one period of ultrasonic oscillation, are captured. Because UVC induced an intermittent cutting condition, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. The ideal chip-generating period is calculated by relative motion between tool and work. We found that the actual chip-generating period was extremely longer than ideal period.

Effects of Cooling Conditions on Thermal Crack Initiation of Brittle Cutting Tools during Intermittent Cutting

2015 ◽  
Vol 656-657 ◽  
pp. 237-242
Author(s):  
Kenji Yamaguchi ◽  
Tsuyoshi Fujita ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
Mitsugu Yamaguchi ◽  
...  
Keyword(s):  
Crack Initiation ◽  
Thermal Shock ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Thermal Crack ◽  
Cooling Conditions ◽  
Cutting Operation ◽  
Intermittent Cutting

It is well known that a series of cracks running perpendicular to the cutting edge are sometimes formed on the rake face of brittle cutting tools during intermittent cutting. The cutting tool is exposed to elevated temperatures during the periods of cutting and is cooled quickly during noncutting times. It has been suggested that repeated thermal shocks to the tool during intermittent cutting generate thermal fatigue and result in the observed thermal cracks. Recently, a high speed machining technique has attracted attention. The tool temperature during the period of cutting corresponds to the cutting speed. In addition, the cooling and lubricating conditions affect the tool temperature during noncutting times. The thermal shock applied to the tool increases with increasing cutting speed and cooling conditions. Therefore, to achieve high-speed cutting, the evaluation of the thermal shock and thermal crack resistance of the cutting tool is important. In this study, as a basis for improving the thermal shock resistance of brittle cutting tools during high-speed intermittent cutting from the viewpoint of cutting conditions, we focused on the cooling conditions of the cutting operation. An experimental study was conducted to examine the effects of noncutting time on thermal crack initiation. Thermal crack initiation was found to be restrained by reducing the noncutting time. In the turning experiments, when the noncutting time was less than 10 ms, thermal crack initiation was remarkably decreased even for a cutting speed of 500 m/min. In the milling operation, the number of cutting cycles before thermal crack initiation decreased with increasing cutting speed under conditions where the cutting speed was less than 500 m/min. However, when the cutting speed was greater than 600 m/min, thermal crack initiation was restrained. We applied the minimal quantity lubrication (MQL) coolant supply to the intermittent cutting operation. The experimental results showed that the MQL diminished tool wear compared with that under the dry cutting condition and inhibited thermal crack initiation compared with that under the wet cutting condition.

Optimal Rough Cutting Tool Path on Cross Sections of Sculptured Surface

1996 ◽  
Author(s):  
Hi K. Lee ◽  
Gyun E. Yang ◽  
Beom S. Ryuh ◽  
Se H. Park
Keyword(s):  
Cutting Force ◽  
Cross Sections ◽  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
Optimal Path ◽  
Cutting Speed ◽  
Sculptured Surface ◽  
Nc Milling ◽  
Cutting Path

Abstract The optimal tool path for NC milling of a sculptured surface is given on cross sections of the surface, which extends the application of contour tool path from 2 dimensional milling to 3-axis and 5-axis milling. The cutting speed in rough cutting is the main objective of the optimal path. The contour tool path on cross sections of the surface can generate the rough cutting path in high speed without excessive cutting force, chatter and heavy wear of the cutting tool. Also, the path can be expanded to 3 -axis and 5-axis milling for machining of complicated surfaces.

Optimization of Cutting/Tool Parameters for Dry High-Speed Spiral Bevel and Hypoid Gear Cutting with Cutting Simulation Experiment

2012 ◽  
Vol 472-475 ◽  
pp. 2088-2095 ◽  
Author(s):  
Gan Hua Liu ◽  
Hong Zhi Yan ◽  
Jun Jie Zhang
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Hypoid Gear ◽  
Gear Cutting ◽  
Relief Angle ◽  
Spiral Bevel

Tool life and the rationality of cutting parameter setting are evaluated directly by cutting force. In order to predict cutting force, and then to optimize the tooth cutting condition for dry high-speed spiral bevel and hypoid gear cutting, this study has established a 2D cutting FEM simulation platform by using DEFORM-2D based on the 2D orthogonal slot milling experiment. Through the platform, using the method of combining single-factor experiment and multi-factor orthogonal experiment, this study has explored the influence of cutting/tool parameters on cutting force in the dry high-speed cutting process of 20CrMnTi spiral bevel and hypoid gear (face hobbing dry cutting process). The results show that from high degree to low degree, the influence of each parameter on cutting force is as follows: feed > cutting speed > relief angle(P.A.side) >blade rake angle, and the influence of the first three parameters is significant, the influence of blade rake angle is not significant; the optimized condition for dry high-speed spiral bevel and hypoid gear cutting is suggested to be: the cutting speed is 300 m/mim, the feed is 0.06 mm/r, the blade rake angle is 14° and the relief angle(P.A.side) is 10°; the cutting edge can be honed moderately, but the hone radius is not bigger than 0.1 mm.

scholarly journals Machinability of SMART Forging Process Materials in Intermittent Cutting: 2nd Report : Machinability in Normal Cutting Region and Selection of Optimum Cutting Condition

2019 ◽  
Vol 95 ◽  
pp. 01001
Author(s):  
Mitsuaki Murata ◽  
Makoto Hino ◽  
Ryoichi Kuwano ◽  
Syuhei Kurokawa
Keyword(s):  
High Speed ◽  
Combustion Engine ◽  
Hot Forging ◽  
Cutting Speed ◽  
Maximum Speed ◽  
Cutting Condition ◽  
High Speed Cutting ◽  
Cutting Experiments ◽  
Intermittent Cutting ◽  
Selection Of

Transmission used in automobiles is indispensable from the viewpoint of improvement of maximum speed, quietness and fuel consumption even if the power source of automobile is changed from internal combustion engine to electric motor in the future. We are studying a heat treatment process for imparting machinability to the forged material after hot forging used for a transmission of automobiles. In the past, the heat stored in the material after hot forging was merely released into the atmosphere. We succeeded in imparting machinability to the material by cooling while well controlling the heat stored in the forged material after hot forging. In the previous paper [1], we reported the progress of tool wear of this forged material in the high-speed cutting region with the cutting speed of 200 m/min or more in intermittent cutting. In this report, we conducted cutting experiments on the machinability of this developed forged material in the normal cutting speed region with the cutting speed less than 200 m/min. As a result, at the cutting speed V of V=157 m/min or less, it reached the conclusion that the built-up edges frequently occurred and the tool was chipped due to it. From the previous report and the results of this experiment, it was found that the cutting speed V of about V=213 m/min is optimum for cutting these forged materials with cemented carbide.

Visualization of Dynamically Changing Cutting Force Under Ultrasonic Cutting Condition

2020 ◽  
Author(s):  
Hiromi Isobe ◽  
Masataka Okuda ◽  
Keisuke Hara ◽  
Akira Sakurada ◽  
Jun Ishimatsu
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Dynamic Change ◽  
Rake Angle ◽  
Cutting Condition ◽  
Ultrasonic Frequency ◽  
Vibration Direction ◽  
Vibration Period ◽  
Intermittent Cutting

Abstract The aim of this study is to investigate the dynamic phenomenon of ultrasonic vibration-assisted cutting condition by utilizing visualization system of stress distribution. The vibrating cutting edge is considered to be cause of dynamic change of cutting force at ultrasonic frequency. However, many researchers have explained the effect of ultrasonic vibration-assisted cutting by evaluating the time-averaged cutting force, because the dynamometers have insufficient frequency characteristics to measure the dynamically changing cutting force in ultrasonic frequency. In this study, the instantaneous stress distribution on workpiece was visualized by photoelastic method in combination of pulse laser emission synchronized with tool vibration. A constructed photographic system is able to capture 360 flames for one ultrasonic vibration period. Dynamic cutting force is calculated by stress distribution by Flamant theory. It was experimentally confirmed that the stress distribution under vibration-assisted condition showed the periodical change synchronized with insert vibration. Because these results are compatible with well-known vibration cutting theories, the imaging system is able to show the periodic change of stress distribution in ultrasonic frequency band. It is considered that the dynamic change of cutting force for ultrasonic vibration period affects intermittent cutting condition. In this report, the vibration direction was adjusted from −9.54° to +9.5° to the cutting direction. When the tool moved in upward for the cutting phase and downward for withdrawal phase, the stress distribution continued to be observed over one period of tool vibration and intermittent cutting did not occurred. The locus of cutting force vector was affected by the ultrasonic vibration direction and rake angle of cutting tool. Negative rake angle showed that the direction of the cutting force vector shifted to the workpiece side near the most advanced position of the cutting edge.

scholarly journals Pengaruh pemesinan laju tinggi keadaan kering terhadap pertumbuhan aus sisi (VB) pahat karbida berlapis (tialn/tin) pada pembubutan paduan aluminium 6061

2018 ◽  
Vol 16 (2) ◽  
pp. 51
Author(s):  
Sunarto Sunarto ◽  
Sri Mawarni
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Coating Materials ◽  
High Cutting Speed ◽  
Titanium Nitride Coating ◽  
Cnc Lathe

AbstrakPemesinan laju tinggi yang diindikasikan dengan kecepatan potong tinggi pada proses pembubutan keadaan kering menjadi bahasan utama pada penelitian ini. Kecepatan potong (Vc) merupakan salah satu penyebab meningkatnya temperatur pemotongan dan akan mempengaruhi daya tahan alat potong. Akibat temperatur pemotongan yang tinggi pahat akan mengalami kerusakan salah satunya berupa Aus Sisi (VB). VB akan tumbuh secara terus menerus seiring dengan waktu pemotongan. Tujuan penelitian ini adalah untuk mengetahui pengaruh pemesinan laju tinggi terhadap laju pertumbuhan VB selama proses pembubutan paduan Aluminium 6061. Metode yang digunakan dalam penelitian ini adalah dengan menggunakan pahat karbida (Wc+Co) yang dilapisi dengan bahan pelapis Titanium Aluminium Nitrida dan Titanium Nitrida (TiAlN/TiN) menggunakan mesin bubut CNC serta membagi tiga kondisi pemotongan yaitu pada kecepatan potong 800 m/menit, 1000 m/menit dan 1200 m/menit. Hasil yang dicapai dari kondisi pemotongan tersebut adalah pada kecepatan potong 1200 m/menit menghasilkan ukuran VB yang lebih besar jika dibandingkan dengan kecepaatan potong 800 m/menit dan 1000 m/menit dengan waktu pemotongan masing-masing selama enam menit.Kata Kunci: Kecepatan Potong (Vc), Aus Sisi (VB), Alat PotongAbstractHigh speed machining which is indicated by high cutting speed in the dry lathe process becomes the main discussion in this study. The cutting speed (Vc) is one of the causes of increasing the cutting temperature and will affect the durability of the cutting tool. Due to high cutting temperature the cutting tool will suffer damage one of them is Flank Wear (VB). VB will grow continuously along with the cutting time. The purpose of this research is to know the effect of high speed machining to growth rate of VB during the process of Aluminum 6061 alloy. The method used in this research is by using  cutting tool (Wc + Co) coated with Titanium Aluminum Nitride and Titanium Nitride coating materials (TiAlN / TiN) using CNC lathe and dividing the three cutting conditions ie at cutting speed of 800 m / min, 1000 m / min and 1200 m / min. The result of the cutting condition is at a cutting speed of 1200 m / min resulting in a larger VB size when compared to 800 m / min cutting speed and 1000 m / min with each cutting time of six minutes.Keywords: Cutting Speed (Vc), Flank Wear (VB), Cutting Tool

Effect of Machining Parameters on Cutting Force when Turning Untreated and Sb-Treated Al-11%Si-1.8%Cu Alloys Using PVD Coated Tools

2012 ◽  
Vol 234 ◽  
pp. 74-77 ◽  
Author(s):  
Mohsen Marani Barzani ◽  
Mohd Yusof Noordin ◽  
Saaed Farahany ◽  
Ali Ourdjini
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Coated Tools ◽  
Cu Alloys ◽  
Cutting Speeds

One of the important aspects of machining is the measurement of the cutting forces acting on the tool. The information of forces is required for evaluation of power requirements, designing tool holder, machine tool elements and fixture. In this research, the effect of cutting condition on cutting force when turning untreated Al-11%Si-1.8%Cu and Sb-treated alloys was investigated. PVD TiN coated insert as cutting tool under oblique dry cutting process utilized. Experiments were conducted at three different cutting speeds of 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut was kept constant at 0.05 mm. The results revealed that turning of Sb-treated alloys requires higher cutting force in comparison to untreated alloy. The cutting force values increased about four times with increasing feed rate from 0.05 mm/rev to 0.15 mm/rev. Furthermore, the cutting force decreased with increasing cutting speed from 70 m/min to 250 m/min.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

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