The Simulation of the Influence of Honed Edge Radius on the Maximum Temperature in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 399-401 ◽  
pp. 1848-1851
Author(s):  
Yi Dan Zhou ◽  
Tao Wang
Keyword(s):  
Metal Cutting ◽  
Cutting Temperature ◽  
Simulation Software ◽  
Cutting Edge ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of 42CrMo with three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the maximum temperature of cutting area. According to the simulation, the maximum temperature does not absolutely increase with the honed edge radius increase. The cutting temperature reaches maximum when the honed edge radius is 0.06mm in this paper, meanwhile the margin of fluctuation in the smallest.

The Simulation of the Influence of Honed Edge Radius on the Cutting Force and Torque in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 130-134 ◽  
pp. 1779-1784
Author(s):  
Tao Wang ◽  
Ya Shi Ke ◽  
Yi Dan Zhou
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Simulation Software ◽  
Cutting Edge ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the the cutting force and torque. According to the simulation, the z-axis force and torque increase while the margin of the fluctuation decrease with the honed edge radius increase. In this paper, the z-axis force and torque reach the maximum and the margin of fluctuation in the smallest when using the honed edge radius of 0.10mm.

Drilling of bone: Effect of drill bit geometries on thermal osteonecrosis risk regions

2018 ◽  
Vol 233 (2) ◽  
pp. 207-218 ◽  
Author(s):  
Mohd Faizal Ali Akhbar ◽  
Ahmad Razlan Yusoff
Keyword(s):  
Ex Vivo ◽  
Helix Angle ◽  
Simulation Software ◽  
Drilling Process ◽  
Drill Bit ◽  
Temperature Elevation ◽  
Bone Drilling ◽  
Drilling Simulation ◽  
Deform 3D ◽  
Bone Effect

Bone-drilling operation necessitates an accurate and efficient surgical drill bit to minimize thermal damage to the bone. This article provides a methodology for predicting the bone temperature elevation during surgical bone drilling and to gain a better understanding on the influences of the point angle, helix angle and web thickness of the drill bit. The proposed approach utilized the normalized Cockroft–Latham damage criterion to predict material cracking in the drilling process. Drilling simulation software DEFORM-3D is used to approximate the bone temperature elevation corresponding to different drill bit geometries. To validate the simulation results, bone temperature elevations were evaluated by comparison with ex vivo bone-drilling process using bovine femurs. The computational results fit well with the ex vivo experiments with respect to different drill geometries. All the investigated drill bit geometries significantly affect bone temperature rise. It is discovered that the thermal osteonecrosis risk regions could be reduced with a point angle of 110° to 140°, a helix angle of 5° to 30° and a web thickness of 5% to 40%. The drilling simulation could accurately estimate the maximum bone temperature elevation for various surgical drill bit point angles, web thickness and helix angles. Looking into the future, this work will lead to the research and redesign of the optimum surgical drill bit to minimize thermal insult during bone-drilling surgeries.

Study on Cutting Temperature Modeling of Machined Workpiece in End Milling In-Situ TiB2/7050Al MMCs

2018 ◽  
Author(s):  
Yifeng Xiong ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin
Keyword(s):  
Heat Source ◽  
Metal Cutting ◽  
End Milling ◽  
Great Influence ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Temperature Model ◽  
Machined Surface ◽  
Temperature Modeling

During metal cutting, it is well known that the cutting temperature has great influence on the machined surface integrity, especially on the residual stress and machining defects. At present, a lot of analytical modeling work has been done on the cutting temperature of tool, chips and workpiece machined by the side cutting edge during end milling process. To the workpiece surface machined by the bottom cutting edge, the study of temperature modeling is rarely reported. Besides, as a new kind of particulate metal matrix composites (MMCs) with improved mechanical and physical properties, the machining study of in-situ TiB2/7050Al MMCs is not many and no analytical temperature modeling of MMCs has been published up to now. Our study aims to establish an analytical cutting temperature model of workpiece machined by the bottom cutting edge in end milling in-situ TiB2/7050Al MMCs. In this model, the moving heat source method was applied. To meet the actual cutting process, the effect of heating time was also taken into account. With validation, the temperature model shows good agreement with experimental results. It was found that the heat partition ratio conducted from the shear plane heat source to the workpiece increased linearly as thermal number increased, due to the influence of increasing heat conducted into chip by the side cutting edge. The proposed cutting temperature model was of great significance for both the temperature modeling work of end milling and study of Al-MMCs.

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.

Edge Design for Regrinding Cutting Tool

2011 ◽  
Vol 101-102 ◽  
pp. 938-941
Author(s):  
Xin Li Tian ◽  
Hao Wang ◽  
Xiu Jian Tang ◽  
Zhao Li ◽  
Ai Bing Yu
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Edge Angle ◽  
Edge Radius ◽  
Tool Edge ◽  
Edge Defects ◽  
Tool Cutting ◽  
Edge Preparation

Regrinding of wasted cutting tools can recycle resources and decrease manufacturing costs. Influence of relative tool sharpness and tool cutting edge angle on tool edge radius were analyzed. Cutting force and cutting temperature were simulated with FEM on different edge radius. Edge preparation experiments were carried out though an abrasive nylon brushing method. The results show that RTS and cutting edge angle have influence on edge radius. Small edge radius might result in small cutting forces and lower average temperatures, could maintain the cutting state between tool and workpiece. The cutting edge defects can be eliminated through edge preparation, and a smooth cutting edge can be obtained. Cutting tool life will be improved through proper edge design and edge preparation.

A Model for the Prediction of Thermal Response of Bone in Surgical Drilling

2014 ◽  
Vol 6 (4) ◽  
Author(s):  
Nazanin Maani ◽  
Kambiz Farhang ◽  
Mohammad Hodaei
Keyword(s):  
Control Volume ◽  
Thermal Response ◽  
Adaptive Mesh ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Drill Bit ◽  
Bone Chip ◽  
Lumped Parameter ◽  
Rough Surface Contact ◽  
Parameter Approach

This paper develops a mathematical model for predicting the thermal response in the surgical drilling of bone. The model accounts for the bone, chip, and drill bit interactions by providing a detailed account of events within a cylindrical control volume enveloping the drill, the cut bone chip within the drill bit flute, and the solid bone. Lumped parameter approach divides the control volume into a number of cells, and cells within the subvolumes representing the drill solid, the bone chip, and the bone solid are allowed to interact. The contact mechanics of rough surfaces is used to model chip–flute and chip–bone frictional interaction. In this way, not only the quantification of friction due to sliding contact of chip–flute and chip–bone rough surface contact is treated but also the contact thermal resistances between the rubbing surfaces are included in the model. A mixed combination of constant and adaptive mesh is employed to permit the simulation of the heat transfer as the drill bit penetrates deeper into the bone during a drilling process. Using the model, the effect of various parameters on the temperature rise in bone, drill, and the chip is investigated. It is found that maximum temperature within the bone occurs at the location adjacent to the corner of the drill-tip and drill body. The results of the model are found to agree favorably with the experimental measurements reported within the existing literature on surgical drilling.

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 DRILL BIT SELECTION USING DESIGN OF EXPERIMENTS (DoE) METHOD

2020 ◽  
Vol 3 (01) ◽  
pp. 39-43
Author(s):  
Rieza Zulrian Aldio ◽  
Zainol Mustafa
Keyword(s):  
Metal Cutting ◽  
Critical Factor ◽  
Significance Test ◽  
Industrial Sector ◽  
Drilling Process ◽  
Drill Bit ◽  
Effect Analysis ◽  
Drill Point ◽  
Cutting Processes ◽  
Selection Of

Drilling process is one of the most common machning process in industrial sector. More than half of the metal-cutting processes are conducted by the drilling process. Drill bit has influenced the results of the drilling process. Therefore, selection of the suitable drill bit becomes a critical factor in the drilling process. This is because the use of the suitable drill bit could fulfill the determined specification value of the hole. Six Sigma and Failure Mode Effect Analysis (FMEA) methods are used to identify factors that have influenced the results of the drilling process. Then by using the Design of Experiment, selection of the best drill bit could be done. In this study, 2 factors that influenced the result are the drill bit type and the drill point angle. Significance test using nested design through MINITAB 14 application has shown that both factors have significant influence over the hole diameter size.. Then by using the plot from the MINITAB 14 application, HPMT 1 became the best drill bit because it could fulfill the specification value. As for the best point angle in this study is 139.72º. Process capability calculation of HPMT 1 has shown that the process is in control. The conclusion is that drill bit HPMT 1 with point angle 139.72º became the best option in this study.

scholarly journals Effect of drilling parameters on drilling temperature and force of ultra-high strength steel

2019 ◽  
Vol 23 (5 Part A) ◽  
pp. 2577-2584
Author(s):  
Hui Zhang ◽  
Changsheng Guo ◽  
Changming Zhang
Keyword(s):  
Axial Force ◽  
Prediction Models ◽  
Cutting Temperature ◽  
Spindle Speed ◽  
Cutting Edge ◽  
Test Method ◽  
Drilling Process ◽  
Temperature Decrease ◽  
Drilling Temperature ◽  
Drilling Parameters

Aiming at 300M hard-to-machine material, the effects of different drilling parameters (spindle speed, n, feed, f, bit diameter, d) on drilling temperature, torque and axial force were analyzed and studied by orthogonal test method. The prediction models of drilling temperature, torque, and drilling axial force are constructed. The results show that the cutting temperature and stress are mainly distributed on the cross edge of the bit in the initial stage of 300 m steel drilling. With the continuous drilling process of 300M hard-to-machine materials, the cutting temperature and stress generated gradually transfer to the main cutting edge of the bit and extend along the main cutting edge. With the increase of bit diameter, the cutting axial force, torque and cutting temperature decrease, but the cutting axial force, torque and cutting temperature decrease. With the increase of spindle speed and feed, the cutting temperature is increasing. According to the results of orthogonal experiment, the cutting axial force is established by least square method. The predictive models of force, torque, and cutting temperature are validated by the experimental model coefficients and model coefficients. The results show that feed, f, has the greatest influence on cutting axial force, torque, and cutting temperature.

Lubrication Effect of Smeared Oil on Workpiece Surface in Intermittent Cutting With Very Short Cutting Duration

2020 ◽  
Author(s):  
Yoshiki Nakamura ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Satoru Maegawa ◽  
Xiaoxu Liu
Keyword(s):  
Cutting Force ◽  
Temperature Rise ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Frictional Heat ◽  
Low Viscosity ◽  
Ti Alloys ◽  
Intermittent Cutting

Abstract In the metal cutting, generally, application of lubricant to a cutting edge is one of the methods in order to suppress temperature rise of the cutting edge by reducing frictional heat. However, the reduction in friction with lubricant disappears at higher temperature environment because of the loss of lubricant oiliness associated with temperature rise. Conversely, this reduction effect might work only in the initial stage immediately after cutting edge /work engagement because the temperature is not so high. Therefore, if the cutting duration of each blade of end-mill is shorten by limiting the cutting length per once, the cutting temperature can be suppressed to be lower than the moderate magnitude for lubrication. On the other hand, Ti-alloys with low thermal conductivity would experience quite high temperature increase during the high-speed cutting process. Therefore, it is thought that lubricant cannot be used properly with conventional cutting methods. In this study, the high-speed milling method mentioned above was used to implement the machining of Ti-alloys, and the lubricant effects of different types oils were compared from two aspects as tool wear and cutting force. As a result, when using low-viscosity synthetic ester oil, the damage to the cutting edge was suppressed most. At the same time, there was no fluctuation in cutting force by repeated machining. From this result, it was suggested that the lubricant performance, in intermittent cutting with very short cutting duration, depends on the heat resistance and permeability of the oil.

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