Study on Cutting Force of Diamond Cutter in Special-Shaped Stone Processing

2011 ◽  
Vol 291-294 ◽  
pp. 804-809 ◽  
Author(s):  
Bo Huang ◽  
Zeng Wen Liu
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Key Factors ◽  
Peripheral Speed ◽  
Factors Influencing ◽  
Relationship Of ◽  
The Relationship

The cutting force is the key factors influencing the processing precision and efficiency in special-shaped stone production. In this research, the cutting force is measured and analyzed in the process of special shaped cutter cutting stone. It is found that the relationship of cutting force with peripheral speed of cutter is nearly inverse proportional. The cutting force becomes smaller and smaller as the peripheral speed of cutter increases. The relationship of cutting force with feed rate is nearly proportional. The cutting force becomes larger and larger as the feed rate increases. The relationship between Fx, Fy and Fz is Fz > Fx > Fy. Enhancing the peripheral speed of cutter is a better way to increase the material removal rate.

scholarly journals MULTI-OBJECTIVE OPTIMIZATION OF TURNING PROCESS USING A COMBINATION OF TAGUCHI AND VIKOR METHODS

2021 ◽  
pp. 1-6
Author(s):  
Nhu-Tung Nguyen ◽  
Van Thien Nguyen ◽  
Dung Hoang Tien ◽  
Duc Trung Do
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Optimization Problem ◽  
Removal Rate ◽  
Multi Objective Optimization ◽  
Nose Radius ◽  
Multi Objective ◽  
Cutting Velocity

This study presents the solving process of the multi-objective optimization problem using VIKOR method (Vlse Kriterijumska Optimizacija Kompromisno Resenje, in Serbian) when turning the EN 10503 steel. The cutting velocity, feed rate, depth of cut, and insert nose radius were chosen as the input parameters with three levels of each parameter. Taguchi L9 orthogonal array was used to design the experimental matrix with nine experiments. By the combination of Taguchi and VIKOR methods, the multi-objective optimization problem was successfully solved with optimal values (cutting velocity of 78.62 m/min, feed rate of 0.08 mm/rev, cutting depth of 0.5 mm, and insert nose radius of 0.4 mm. Using these the optimized input parameters, the surface roughness, cutting force and vibration component amplitudes (in X, Y, Z directions), and material removal rate (MRR) were 0.621 µm, 191.084 N, 300.162 N, 51.727 N, 4.465 µm, 7.492 µm, 10.118 µm, and 60.009 mm3/s, respectively. This proposed method could be used to improve the quality and effectiveness of turning processes by improving the surface quality, reducing the cutting force and vibration amplitudes, and increasing the material removal rate.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Parametric Study of Micro Machining Three Dimensional Microstructure with the Tiny-Grinding Wheel Based on the EMR Effect

2010 ◽  
Vol 447-448 ◽  
pp. 193-197
Author(s):  
Wei Qiang Gao ◽  
Qiu Sheng Yan ◽  
Yi Liu ◽  
Jia Bin Lu ◽  
Ling Ye Kong
Keyword(s):  
Magnetic Field ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Machining Time ◽  
Fluctuation Phenomenon

Electro-magneto-rheological (EMR) fluids, which exhibit Newtonian behavior in the absence of a magnetic field, are abruptly transformed within milliseconds into a Bingham plastic under an applied magnetic field, called the EMR effect. Based on this effect, the particle-dispersed EMR fluid is used as a special instantaneous bond to cohere abrasive particles and magnetic particles together so as to form a dynamical, flexible tiny-grinding wheel to machine micro-groove on the surface of optical glass. Experiments were conducted to reveal the effects of process parameters, such as the feed rate of the horizontal worktable, feeding of the Z axis, machining time and machining gap, on material removal rate of glass. The results indicate that the feed rate of the worktable at horizontal direction has less effect on material removal rate, which shows a fluctuation phenomenon within a certain range. The feed rate of the Z axis directly influences the machining gap and leads to a remarkable change on material removal rate. Larger material removal rate can be obtained when the feeding frequency of Z direction is one time per processing. With the increase of rotation speed of the tool, material removal rate increases firstly and decreases afterwards, and it gets the maximum value with the rotation speed of 4800 rev/min. The machining time is directly proportional to material removal amount, but inversely proportional to material removal rate. Furthermore, material removal rate decreases with the increase of the machining gap between the tool and the workpiece. On the basis of above, the machining mode with the tiny-grinding wheel based on the EMR effect is presented.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Wear Characteristics of the Sub-Aperture Tools and Material Removal Rate in Precision Grinding with Loose Abrasives

2007 ◽  
Vol 329 ◽  
pp. 69-74
Author(s):  
H. Cheng ◽  
H.Y. Tam ◽  
Y. Gao ◽  
Yong Bo Wu ◽  
Y. Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Process Analysis ◽  
Actual Process ◽  
Correlative Function ◽  
Glass Specimen ◽  
Grinding Tool ◽  
The Relationship

This paper proposes a sub-aperture grinding tool for loose abrasive computer controlled surfacing, which is designed to perform epicyclic motion and rotate around its centre at a rapid rate, whilst the entire mechanism revolves around a secondary centre at a slower rate. In actual process, the wear of the tool could affect the material removal function, and make the process unstable, thus in fact, it is difficult to make a deterministic manufacturing. The focus of the present paper is on wearing characteristics of sub-aperture tools and the wear evenness as the main objectives. To make a further study, material removal function of the tool is firstly established through theoretically modelling, next, a correlative function with weighted factors is built, which is suitable for specifying the wearing degree of the tool. Finally, to discover the relationship between the material removal rate and the tool wearing characteristics, and to optimize the grinding process, analysis and experiments are then carried out on a K9 glass specimen by means of three kinds of tool materials, i.e., polyurethane pad, aluminum plate and pitch based on the proposed technique and model. The results indicated that the required high efficiency and precision could be achieved by choosing proper processes.

The Quantitative Evaluation on the Lapping Uniformity of Rotated Dual-Plates Lapping Mode

2010 ◽  
Vol 37-38 ◽  
pp. 1534-1539 ◽  
Author(s):  
Ping Zhao ◽  
Wei Yu ◽  
Ke Feng Tang ◽  
Bing Hai Lv ◽  
Ju Long Yuan
Keyword(s):  
Material Removal Rate ◽  
Basic Principle ◽  
Material Removal ◽  
Removal Rate ◽  
Contact Point ◽  
Bearing Steel ◽  
Basic Rule ◽  
Speed Ratio ◽  
Key Factors ◽  
Ball Surface

The lapping trace distribution on ball surface is one of the key factors during the lapping process, which can affect the sphericity of lapping. The Rotated Dual-Plates lapping mode (RDP lapping mode) can achieve better uniformity of lapping trace distribution on precision ball surface, which ensure the results of forming sphere by lapping. Combining with the basic principle of RDP lapping mode, as well as the analysis of the kinematics of the RDP lapping method, this paper puts forward a basic rule about the material removal at the contact point between the ball and the plate with the material removal rate equation of bearing steel, and the improvement of the sphericity which can be simulated, and is defined as the lapping uniformity according to basic rule equation. The influence caused by the lapping pressure and the speed of the plates are considered in the simulation, the surface of ball is triangle grid divided. The uniformity of lapping is evaluated at different speed ratio, and eventually a better curve of the speed ratio can be got, so the lapping uniformity during the RDP lapping mode can finally be accurately evaluated.

The Influence of the Grinding Force to the Material Removal Rate in the Heavy Load Honing

2011 ◽  
Vol 63-64 ◽  
pp. 719-722
Author(s):  
Jian Ye Guo ◽  
Chao Yu ◽  
Guang Qi Cai
Keyword(s):  
Mathematical Model ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Processing Technology ◽  
Heavy Load ◽  
Theoretical Significance ◽  
The Mathematical Model ◽  
The Relationship

This paper took the grinding force in the heavy load honing as the object to research, it mainly analyzed the influence of the grinding force to the material removal rate. First the mathematical model of grinding force was established from starting with the honing pressure. Then the mathematical model of material removal rate was established according to the relationship between material removal volume and honing pressure. Finally the influence of the honing pressure to the material removal rate was analyzed with the aid of software. The results of this paper have important theoretical significance to optimize the processing technology of heavy load honing and further enhance the machining precision and the honing efficiency.

Research on Microscopic Grain-Workpiece Interaction in Grinding through Micro-Cutting Simulation, Part 2: Factorial Study

2009 ◽  
Vol 76-78 ◽  
pp. 15-20 ◽  
Author(s):  
Lan Yan ◽  
Xue Kun Li ◽  
Feng Jiang ◽  
Zhi Xiong Zhou ◽  
Yi Ming Rong
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Specific Cutting Force ◽  
Single Grain

The grinding process can be considered as micro-cutting processes with irregular abrasive grains on the surface of grinding wheel. Single grain cutting simulation of AISI D2 steel with a wide range of cutting parameters is carried out with AdvantEdgeTM. The effect of cutting parameters on cutting force, chip formation, material removal rate, and derived parameters such as the specific cutting force, critical depth of cut and shear angle is analyzed. The formation of chip, side burr and side flow is observed in the cutting zone. Material removal rate increases with the increase of depth of cut and cutting speed. Specific cutting force decreases with the increase of depth of cut resulting in size effect. The shear angle increases as the depth of cut and cutting speed increase. This factorial analysis of single grain cutting is adopted to facilitate the calculation of force consumption for each single abrasive grain in the grinding zone.

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