Formation and Control of Two Side Direction Burr

2007 ◽  
Vol 24-25 ◽  
pp. 39-44 ◽  
Author(s):  
Gui Cheng Wang ◽  
Chun Gen Shen ◽  
Hong Jie Pei ◽  
Yun Ming Zhu ◽  
Qin Feng Li ◽  
...  
Keyword(s):  
Plane Stress ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Strain Theory ◽  
Burr Formation ◽  
Stress Strain ◽  
Cutting Operation ◽  
And Control ◽  
Cutting Model ◽  
Cutting Experiments

Based on the orthogonal cutting experiments, the two side direction burrs in metal cutting were studied. In this study, the cutting model of two side direction burr formation and translation is established with plane stress-strain theory. The main laws of formation and change of burr in size and type in orthogonal cutting are revealed, and it is confirmed by experiment results, which first realizes control of the forming and change of the two side direction burr in metal cutting operation.

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.

scholarly journals Analysis of critical negative rake angle and friction characteristics in orthogonal cutting of AL1060 and T2

2019 ◽  
Vol 103 (1) ◽  
pp. 003685041987806 ◽  
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi ◽  
Hua Zhang ◽  
Guoquan Shi ◽  
Dongdong Han
Keyword(s):  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Flow Characteristics ◽  
Rake Angle ◽  
Machined Surface ◽  
Friction Characteristics ◽  
Model Based ◽  
Stagnant Region ◽  
Cutting Experiments

The stagnant region often appears in front of the tool cutting edge, which is caused by mechanical inlay and excessive pressing in plastic metal cutting with large negative rake angle tools at a low speed. It results in the change of the effective negative rake angle which can affect the flow characteristics of material, the quality of machined surface and the abrasion loss of cutting tools. However, the critical negative rake angle model based on the existence of the stagnant region has not been reported yet. Therefore, in order to investigate the critical negative rake angle value considering the stagnant region, a critical negative rake angle model based on the principle of minimum required energy is established, and the correctness of the theoretical model is verified by orthogonal cutting experiments. At the same time, the influence of the critical value of the large negative rake angle tool on the machined surface quality is studied through different cutting experiments. These experimental results show that the deviations of both experimental and theoretical critical negative rake angle are less than 5% during the orthogonally cutting of the aluminium (AL1060) and copper (T2) materials by the negative rake angle tool. Meanwhile, the critical negative rake angle is related to the adhesive friction coefficient of tool–workpiece contact surface. The analysis of friction characteristics shows that the deviation values of both theoretical and experimental critical negative rake angle are proportional to the coefficient of adhesive friction and the thickness of the stagnant region. Critical negative rake angle has a significant effect on roughness and residual stress of the machined surface.

Formation and Control of Cutting Direction Burr in Machining

2012 ◽  
Vol 443-444 ◽  
pp. 601-606 ◽  
Author(s):  
Gui Cheng Wang ◽  
Qin Feng Li ◽  
Hong Jie Pei ◽  
Hai Jun Qu ◽  
Yun Ming Zhu
Keyword(s):  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Geometric Parameters ◽  
Precision Machining ◽  
Effect Factors ◽  
Main Effect ◽  
And Control ◽  
Cutting Experiments ◽  
Cutting Direction

In this paper, the forming processes, main effect factors and change law of the cutting direction burr in orthogonal cutting have been studied and related theories are analyzed based on the cutting experiments. The result shows that the forming processes of cutting direction burr consist of normal cutting, flexure deformation of end surface of workpiece, plastic effect, continuous cutting and shear-break separating in orthogonal cutting. And a new phenomenon was found that cutting direction burr is formed with the shear-break separation of the chip and workpiece machined surfaces. In addition, the size of cutting-direction burr varies with workpiece materials, cutting parameters and geometric parameters of cutting tool. The study may be important science and practical value in order to control and reduce cutting burr in precision machining.

The Finite Element Simulation of Milling Based on Orthogonal Cutting Model

2012 ◽  
Vol 499 ◽  
pp. 208-212
Author(s):  
Ai Hua Gao ◽  
Fu Rong Wang ◽  
Jian Xin Zhang
Keyword(s):  
Finite Element ◽  
Service Life ◽  
Finite Element Simulation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Machining Process ◽  
Element Simulation ◽  
Basic Parameters ◽  
Cutting Model

The paper make the service life of relieving formed milling cutter as the optimization objective, proceed the simulation study on the mechanical degree of cutter, cutting data. The concrete method is that the orthogonal milling model is established to simulate the simulation milling process, some basic parameters which are obtained in the machining process are analyzed and discussed. The results indicate that the finite element simulation of the metal cutting processing can analyze quantitatively some physical properties, such as the cutting force, stress, strain and so on, the traditional way of qualitative analysis is changed. The state of machining is in favour of grasping in the theory, the theory and technology are provided to establish the proper processing technology strategy.

Formation and Control of Feed Direction Burrs in Machining

2006 ◽  
Vol 532-533 ◽  
pp. 580-583
Author(s):  
Gui Cheng Wang ◽  
Chun Yan Zhang ◽  
Hong Jie Pei ◽  
Yun Ming Zhu ◽  
Li Jie Ma
Keyword(s):  
Physical Parameter ◽  
Metal Cutting ◽  
Theory Analysis ◽  
Related Theory ◽  
Edge Angle ◽  
Feed Direction ◽  
Tool Edge ◽  
Main Factors ◽  
And Control ◽  
Cutting Experiments

Based on the metal cutting experiments, the forming model of feed direction burr is proposed in the paper, a physical parameter of determining the generating of typeⅠ feed direction burr — critical tool edge angle rI χ is given. And the main factors which influence rI χ are studied by the experiment, and related theory analysis is made. Furthermore, some new controlling methods and technology to restrain or decrease the feed direction burr in machining are developed.

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.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

An Orthogonal Cutting Model Based on Finite Deformation Analysis: Part II — Constitutive Equations and Experimental Verification

1999 ◽  
Author(s):  
Y. Zheng ◽  
J. W. Sutherland
Keyword(s):  
Finite Deformation ◽  
Constitutive Equations ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Deformation Analysis ◽  
Tool Steels ◽  
Model Based ◽  
Cutting Operation ◽  
Cutting Experiment ◽  
Cutting Model

Abstract In Part I of this paper, a model based on finite deformation analysis was developed to predict the forces in an orthogonal cutting operation. In the second part of the paper, the constitutive equations for O1 and L6 tool steels are developed using Hopkinson bar tests. A total of 90 statistically designed orthogonal cutting tests are conducted to investigate the cutting mechanics of O1 and L6 tool steels. Then the cutting model developed in Part I of this paper is applied to simulate all the 90 cutting tests using the measured material constitutive equations. All the measurable model outputs are calculated and compared with the corresponding cutting experiment results. The comparisons show that the cutting model based on finite deformation analysis can be successfully applied to predict the cutting forces, shear angle, and various relationships in machining (orthogonal cutting) tests.

High-Speed Cutting Machining Simulation of Aero Engine Casing Hole

2014 ◽  
Vol 915-916 ◽  
pp. 1014-1017 ◽  
Author(s):  
Ting Jian Dong ◽  
Jin Chen ◽  
Hua Peng Ding
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Contact Friction ◽  
Physical Factors ◽  
High Speed Cutting ◽  
Aero Engine ◽  
Cutting Model

For the high-speed machining aero engine casing hole, according to the principle of metal forming and the characteristic of metal cutting plane strain, with selecting some key physical factors of the cutter - chip contact friction and abrasion model, the Cartesian orthogonal cutting model of aero engine casing hole was established by using the Deform, a sort of finite element analysis software. With taking cutting temperature for preferred aim of the cutting parameters, select the appropriate cutting parameters, the aim of aero-engine casing high-speed (cutting speed up to 700m/min) cutting has been achieved by simulation, and the feasibility of the cutting process was researched and confirmed in theoretically by analyzing the cutting force, cutting temperature and tool wear condition.

Modeling and Analysis of the Steering Resistance Moment in Small Tracked Robot

2011 ◽  
Vol 201-203 ◽  
pp. 1939-1948
Author(s):  
Yi Ou ◽  
Si Ji Huang ◽  
Hu Tian Feng ◽  
Wei Jun Tao
Keyword(s):  
High Speed ◽  
Strain Theory ◽  
Modeling Method ◽  
Stress Strain ◽  
Modeling And Analysis ◽  
Lateral Resistance ◽  
Resistance Torque ◽  
Uniform Resistance ◽  
Resistance Moment ◽  
And Control

A modeling method for steering resistance moment in small tracked robot is studied. First of all, Classical steering resistance torque modeling with uniform resistance is studied in low speed and high speed. Then the steering resistance torque modeling while lateral resistance and the pressure are linearly distributed is proposed. After that steering resistance moment modeling based on the stress-strain theory is used to describe the robot's steering resistance above different soil. Among them, the lateral resistance is nonlinear distribution. The driving experiments in three different vehicle terramechanics models are simulated and analyzed. Steering resistance moment modeling based on the stress-strain theory is closer to the actual working state of the robot. This modeling method for steering resistance moment has advantage on optimization and study in and control algorithm.

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