Effect Mechanism of Elliptic Vibration Assistance on the Cutting of Brittle Materials

2012 ◽  
Vol 472-475 ◽  
pp. 499-504 ◽  
Author(s):  
Yun Feng Peng ◽  
Tao Jiang ◽  
Yin Biao Guo ◽  
Zhen Zhong Wang ◽  
Yong Bo Wu
Keyword(s):  
Cutting Force ◽  
Compressive Stress ◽  
Chip Formation ◽  
Brittle Materials ◽  
Shielding Effect ◽  
Effect Mechanism ◽  
Elliptic Vibration ◽  
Formation Zone ◽  
Vibration Assistance ◽  
Cutting Model

A theoretical analysis for the effect mechanism of elliptic vibration assistance on the cutting of brittle materials is presented in this paper. The crack propagation in the chip formation zone in cutting of brittle materials is examined based on an analysis of the geometry and forces in the cutting region. The cutting model shows that the actual undeformed chip thickness is much decreased with elliptic vibration assistance, and the instantaneous rake angle of the cutting tool edge is also in a larger negative value than those in conventional cutting. These two conditions can ensure the compressive stress is much larger than the shear stress during the cutting process. Then the stress intensify factor is suppressed effectively and the shielding effect on the growth of pre-existing flaws is strengthened in the chip formation zone. The removal of brittle material tends to be in ductile mode without fracture. The characteristic examination of cutting force shows that the ratio of thrust force to cutting force with elliptic vibration is increased compared to that of conventional cutting. This can validate that the larger compressive stress can be generated in the chip formation zone with elliptic vibration assistance. The transition depth to brittle machining of silicon carbide with/without elliptic vibration assistance further supports the presented theory.

Research on the Ductile Chip Formation in Grinding of Brittle Materials

2011 ◽  
Vol 487 ◽  
pp. 58-62
Author(s):  
Yun Feng Peng ◽  
Zhi Qiang Liang ◽  
Yong Bo Wu ◽  
Yin Biao Guo ◽  
T. Jiang ◽  
...  
Keyword(s):  
Shear Stress ◽  
Compressive Stress ◽  
Chip Formation ◽  
Thrust Force ◽  
Brittle Materials ◽  
Chip Thickness ◽  
Force Model ◽  
Theoretical Discussion ◽  
Undeformed Chip Thickness ◽  
Formation Zone

A theoretical discussion has been presented for the ductile chip formation in grinding of brittle materials. The single abrasive grit was dealt with a top-rounded cutter removing material of varying undeformed chip thickness. The force model in the chip formation zone was established. The stress analysis showed that larger compressive stress and shear stress can be generated in the chip formation zone, which shields the growth of pre-existing flaws in the material by suppressing the stress intensity factor. When the stress intensify factor is smaller than fracture toughness and the resolved shear stress exceeds the critical flow stress of the material, the ductile chip is formed. Experiments of monocrystal silicon grinding were conducted. The results show that the thrust force is much larger than the cutting force, which ensures the larger compressive stress in the chip formation zone and the formation of ductile chip.

Theory of Constrained Cutting: Model of Chip Formation with a Developed Plastic-Deformation Zone

2013 ◽  
Vol 762 ◽  
pp. 782-789 ◽  
Author(s):  
A.V. Proskokov
Keyword(s):  
Chip Formation ◽  
Slip Line ◽  
Complex Form ◽  
Curvilinear Coordinates ◽  
Plastic Deformation Zone ◽  
Shear Surface ◽  
Line Field ◽  
Formation Zone ◽  
Orthogonal Curvilinear Coordinates ◽  
Cutting Model

A Model of Chip Formation with a Single Conditional Shear Surface Cannot be Implemented in Determining the Stresses and Strains in the Blank and Chip neither Nor in Determining the Contact Stresses at the Working Sections of the Front and Read Cutter Surfaces. at the same Time, it has been Established Experimentally that the Cut Layer is Converted to Chip in a Plastic Zone of Complex Form. Numerous Attempts have been Made to Simulate this Zone by Constructing Slip-Line Fields. According to Plasticity Theory, Slip Lines Constitute Two Families of Mutually Orthogonal Curvilinear Coordinates, along which the Maximum Tangential Stress Acts. if the Kinematically Possible Slip-Line Field is Constructed, it is Possible to Calculate the Stress–strain State in the Chip-Formation Zone.

Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

1978 ◽  
Vol 100 (2) ◽  
pp. 222-228 ◽  
Author(s):  
E. Usui ◽  
A. Hirota ◽  
M. Masuko
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Analytical Prediction ◽  
Forming Process ◽  
Proposed Model ◽  
Edge Based ◽  
Cutting Model

The paper proposes a new model of chip forming process in three dimensional cutting with single point tool, in which the process is interpreted as a piling up of orthogonal cuttings along the cutting edge. Based upon the proposed model, an energy method similar to the upper bound approach, which enables to predict the chip formation and the three components of cutting force by using only the orthogonal cutting data, is developed. The method is also applied to predict chip formation and cutting force in oblique cutting, plain milling, and groove cutting operations.

Analytical Prediction of Three Dimensional Cutting Process—Part 2: Chip Formation and Cutting Force with Conventional Single-Point Tool

1978 ◽  
Vol 100 (2) ◽  
pp. 229-235 ◽  
Author(s):  
E. Usui ◽  
A. Hirota
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Analytical Prediction ◽  
Nose Radius ◽  
Cutting Model

The cutting model and the energy method to predict chip formation and cutting force, which were proposed in the previous part of this study, are extended to machining with conventional single-point tool. The prediction is always possible in the practical range of cutting conditions regardless of size of cutting and tool geometry, if only orthogonal cutting data under equivalent cutting conditions are in hand. The predicted results are verified to be in good agreement with the experimental results in a wide variety of depth of cut, side and back rake angles, side cutting edge angle, and nose radius.

Chip Formation and Cutting Performance Investigation on Titanium Alloy Machining

2011 ◽  
Vol 264-265 ◽  
pp. 1062-1072
Author(s):  
Shen Yung Lin ◽  
Y.Y. Cheng ◽  
C.T. Chung
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Chip Type ◽  
Cutting Model

First, a 2D orthogonal cutting model for titanium alloy is constructed by finite element method in this study. The cutting tool is incrementally advanced forward from an incipient stage of tool-workpiece engagement to a steady state of chip formation. Cockroft and Latham fracture criterion [1] is adopted as a chip separation criterion. By changing the settings of cutting variables such as cutting speed, depth of cut and tool rake angle to investigate the chip formation process and the variation of cutting performance during titanium cutting simulation. The changes of chip type, cutting force, effective stress/strain and cutting temperature with different cutting condition combinations are thus analyzed. The result demonstrates that the serrated chip type is obviously produced when cutting titanium alloy. Next, water-based and oil-based cutting fluids are employed in conjunction with proper cutting parameter arrangements to perform up-milling experiments. By measuring the cutting force, surface roughness and tool wear to investigate the effect of these combinations of milling variables on the variation of cutting performance for Ti-6Al-4V. The chip shape and cutting force obtained from the experiment are compared with those calculated from simulation. It is shown that there is a good agreement between simulation and experimental results.

Cutting Characteristics of Hard-Brittle Materials Under Nano/Micro Groove Cutting Using a V-Shape Tool

2020 ◽  
Author(s):  
Yoshino Masahiko ◽  
Shen Hao ◽  
Yuki Nakagawa ◽  
Abdallah Abdelkawy
Keyword(s):  
Cutting Force ◽  
Plastic Flow ◽  
Brittle Materials ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Critical Depth ◽  
Single Crystal Diamond ◽  
Critical Depth Of Cut ◽  
Cutting Model ◽  
Groove Cutting

Abstract The cutting characteristics and the critical depth of cut in nano/micro cutting of hard/brittle materials were investigated. A V-shaped single crystal diamond tool with a negative rake angle was used as the tool, and a cutting experiment was conducted by means of the inclined cutting test technique. The effect of rake angle on specific cutting force was also compared with V-groove cutting model based on simple shear plane. It was found that the cutting force increased and the burrs height increased as the rake angle became negative. and it was considered that the plastic flow influenced on the cutting force. It was also found that the critical cutting depth decreases with the decrease of the rake angle. The result of this experiment showed the opposite tendency to previous studies on the critical depth of cut. This is attributed to that, in the V-type tool cutting, the crack growth by increasing plastic flow is more effective than the suppress of cracks growth by increase of hydrostatic pressure.

Experimental Examination of the Impact of Tool Radius on Specific Energy in Microcutting of Granite

2017 ◽  
Vol 139 (4) ◽  
Author(s):  
Miloš Pjević ◽  
Ljubodrag Tanović ◽  
Goran Mladenović ◽  
Biljana Marković
Keyword(s):  
Cutting Force ◽  
Penetration Depth ◽  
Specific Energy ◽  
Brittle Materials ◽  
Experimental Examination ◽  
Workpiece Surface ◽  
Different Shapes ◽  
Tip Radius ◽  
The Impact ◽  
Force Intensity

The paper presents experimental results of microcutting brittle materials (granite). The analysis was conceived on the observed interaction between the workpiece and two tools of different shapes. Experiment was based on scratching the workpiece surface with diamond tools. Applied tools had tip radius R0.2 and R0.15 mm. The experiment determined the changes in the value of perpendicular and tangential components of the cutting force based on the geometric properties of tools, as well as the changes of the specific energy of microcutting granite (Jošanica and Bukovik types). The experiment has shown that reduction of tool radius causes reduction of the cutting force intensity and specific cutting energy. Because of its physical/mechanical properties, more energy is required for micromachining granite “Jošanica” than “Bukovik.” Based on the topography of the surface, the value of critical tool penetration depth was established, after which the brittle fracture is no longer present. For granite “Jošanica” values of critical penetration depth are 6 and 5 μm when micromachining with tools R0.2 and R0.15 mm, while for Bukovik those values are 6.5 and 5.5 μm. The paper should form the basis for understanding the phenomena which occur during microcutting brittle materials.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

Effect of the Cutting Velocity and Heat Treatment on Turning Cutting Forces of an SMA Cu-Al-Be Alloys

2013 ◽  
Vol 758 ◽  
pp. 157-164
Author(s):  
Francisco Valdenor Pereira da Silva ◽  
José Paulo Vogel ◽  
Rodinei Medeiros Gomes ◽  
Tadeu Antonio de Azevedo Melo ◽  
Anna Carla Araujo ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Shape Memory Alloys ◽  
Shape Memory ◽  
Cutting Force ◽  
Shape Memory Effect ◽  
Memory Effect ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Velocity ◽  
Resultant Forces

This work studies the effect of heat treatment and cutting velocities on machining cutting forces in turning of a Cu-11.8%Al-0.55%Be shape memory alloys. The heat treatment was performed to obtain samples with austenite and martensite microstructures. Cutting force was investigated using a 3-component dynamometer in several revolutions and data were analyzed using statistic tools. It was found that the resultant forces were higher in quenched alloy due to the presence of Shape Memory Effect. Chip formation occurred in a shorter time in the sample without the Shape Memory Effect.

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