Study of the Relationship between Cutting Speed, Tool Wear and Machining Forces in Turning with Carbide Tool

2014 ◽  
Vol 902 ◽  
pp. 88-94
Author(s):  
Heraldo J. Amorim ◽  
Augusto O. Kunrath Neto
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Speed ◽  
Average Error ◽  
Machining Forces ◽  
Feed Force ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
The Relationship

The understanding of machining processes comprises the study of phenomena such as: chip formation, cutting forces, tool wear mechanisms and the influence of the cutting parameters and machined materials on them. The aim of this work is to analyze the tool wear effects on machining forces during machining of AISI 1040 and 1045 carbon steels with carbide tool. Long-term machinability tests were performed, in which cutting force, feed force and tool wear were measured. Tool life results were analyzed, with best tool lives found for the AISI 1040 steel for all tested speeds. The other variables were analyzed as function of both time and tool wear. On the time domain, strong dependencies were found for both materials for tool wear, cutting force and feed force. The relationship between cutting force and tool wear showed good correlation for both materials, and the same was observed for feed force and tool wear relationship. Weak influence of cutting speed was observed on the relationship between tool wear and machining forces, which suggest that a single equation can describe them for all studied conditions with reasonable accuracy. The regression results are able to predict cutting forces as a function of tool wear with an average error of about 2.6 % during machining of AISI 1040 and 5.2 % for AISI 1045 steel. For the prediction of feed force as a function of tool wear, the average error is about 5.6 % for AISI 1040 and 7.0 % for the AISI 1045 steel, since a restricted domain is established. Data analysis showed a discontinuity in the behavior of feed force as a function of tool wear near the end of the life of the tools for most tests performed with AISI 1045 and some tests with AISI 1040 that suggest backwall wear, which was further evidenced by sudden change of chip form near the end of tool life in AISI 1040 steel.

scholarly journals Correction and accuracy improvement of non-parallel shear zone model

2018 ◽  
Vol 207 ◽  
pp. 02002
Author(s):  
Yaoke Wang ◽  
Meng Kou ◽  
Wei Ding ◽  
Huan Ma ◽  
Liangshan Xiong
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Shear Zone ◽  
Coordinate Transformation ◽  
Chip Thickness ◽  
Zone Model ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Experimental Values ◽  
1045 Steel

When applying the non-parallel shear zone model to predict the cutting process parameters of carbon steel workpiece, it is found that there is a big error between the prediction results and the experimental values. And also, the former approach to obtain the relevant cutting parameters of the non-parallel shear zone model by applying coordinate transformation to the parallel shear zone model has a theoretical error – it erroneously regards the determinant (|J|) of the Jacobian matrix (J) in the coordinate transformation as a constant. The shape of the shear zone obtained when |J| is not constant is drew and it is found that the two boundaries of the shear zone are two slightly curved surfaces rather than two inclined planes. Also, the error between predicted values and experimental values of cutting force and cutting thrust is slightly smaller than that of constant |J|. A corrected model where |J| is a variable is proposed. Since the specific values of inclination of the shear zone (α, β), the thickness coefficient of the shear zone (as) and the constants related to the material (f0, p) are not given in the former work, a method to obtain the above-mentioned five constants by solving multivariable constrained optimization problem based on experimental data was also proposed; based on the obtained experimental data of AISI 1045 steel workpiece cutting force, cutting thrust, chip thickness, the results of five above-mentioned model constants are obtained. It is found that, compared with prediction from uncorrected model, the cutting force and cutting thrust of AISI 1045 steel predicted by the corrected model with the obtained constants has a better agreement with the experimental values obtained by Ivester.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

Study on Microstructure Character in the Deformable Regions of AISI-1045 Steel Fine Blanking with Negative Clearance

2009 ◽  
Vol 628-629 ◽  
pp. 541-546 ◽  
Author(s):  
J.H. Li ◽  
Wei Fu Fan ◽  
Zhong Mei Zhang
Keyword(s):  
Work Piece ◽  
Micro Hardness ◽  
Fine Blanking ◽  
Metallic Crystal ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Metal Deformation ◽  
Negative Clearance ◽  
1045 Steel ◽  
The Relationship

This paper obtained work piece of fine blanking with negative clearance by experiment. The microstructure and fractography photograph in regions like rollover zone, shearing band, under sheared surface and fracture band were scanned by instrument of scanning electron microscope (SEM-JSM-6360LV). The fine-blanking with negative clearance makes the metal deformation regions into a state of triaxial stress precise and it causes an intense metallic stream that brings about inter-dislocation and distortion of metallic crystal product under the action of stronger force, so the metallic crystal is reset and the isometric metallic crystal of shearing zone is staved, sloped and pulled and it appears as dense lined and strip crystal. The paper analyzes the full course of producing and development of micro crack in the ejecting stage in the fine-blanking processing of negative clearance. And the course of final rupture is also analyzed. The relationship curve of blanking stroke and micro hardness is measured by Vickers Hardness instrument (MH-6). The deforming principle of fine blanking deformation with negative clearance is analyzed by means of microstructure, metallographic photograph and micro hardness.

Prediction of Tool Wear Mechanisms in Face Milling AISI 1045 Steel

2011 ◽  
Vol 21 (6) ◽  
pp. 797-808 ◽  
Author(s):  
Patricia Muñoz-Escalona ◽  
Nayarit Díaz ◽  
Zulay Cassier
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Face Milling ◽  
Tool Wear Mechanisms ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Tool tip cutting specific energy prediction model and the influence of machining parameters and tool wear in milling

2020 ◽  
Vol 234 (10) ◽  
pp. 1346-1354 ◽  
Author(s):  
Guoyong Zhao ◽  
Yu Su ◽  
Guangming Zheng ◽  
Yugang Zhao ◽  
Chunxiao Li
Keyword(s):  
Tool Wear ◽  
Prediction Model ◽  
Specific Energy ◽  
Machine Tools ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Energy Prediction ◽  
Aisi 1045 Steel ◽  
1045 Steel

Most of the existing energy-consumption models of machine tools are related to specific machine components and hence cannot be applied to other machine tools with different specifications. In order to help operators optimize machining parameters for improving energy efficiency, the tool tip cutting specific energy prediction model based on machining parameters and tool wear in milling is developed, which is independent of the standby power of machine tools and the spindle no-load power. Then, the prediction accuracy of the proposed model is verified with dry milling AISI 1045 steel experiments. Finally, the influence of machining parameters and tool wear on tool tip cutting specific energy is studied. The developed model is independent of machine components, so it can reveal the influence of machining parameters and tool wear on tool tip cutting specific energy. The tool tip cutting specific energy reduces with the increase in the cutting depth, side cutting depth, feed rate, and cutting speed, while increases linearly as the tool wears gradually. The research results are helpful to formulate efficient and energy-saving processing schemes on various milling machines.

Assessment of the Performance of Microbumped Cutting Tool in Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Contact Length ◽  
Machining Performance ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

Selection of Optimal Tool Geometry and Cutting Conditions in End Milling With Graphite as a Solid Lubricant

2004 ◽  
Author(s):  
N. Suresh Kumar Reddy ◽  
P. Venkateswara Rao
Keyword(s):  
Solid Lubricant ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performance and overcome some of the limitations that arise with the use of cutting fluids or while machining dry. This paper deals with an investigation on using graphite as a solid lubricant to reduce the heat generated at the milling zone for improving the surface roughness of the machined AISI 1045 steel. An experimental setup has been developed to maintain constant flow rate of graphite powder continuously on to the workpiece and tool interface zone. The experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on the machining response such as surface finish in solid lubricant assisted machining using four fluted solid TiAlN coated carbide cutters. Results indicate that there is a considerable improvement in the performance of milling AISI 1045 steel using graphite as a solid lubricant when compared with machining with cutting fluids. An attempt has also been made to select optimum tool geometry and cutting conditions in end milling with graphite as a solid lubricant by using the prediction model obtained from these experimental results.

FEM Simulation of Machining AISI 1045 Steel Using Driven Rotary Tool

2015 ◽  
Vol 758 ◽  
pp. 77-82 ◽  
Author(s):  
Yanuar Burhannudin ◽  
Suryadiwansa Harun ◽  
Gusri Akhyar Ibrahim
Keyword(s):  
Feed Rate ◽  
Fem Simulation ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Rotary Tool ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Simulation Results ◽  
1045 Steel

This study investigates the influences of driven rotary tool (DRT) on temperatures and forces when turning AISI 1045 steel. A set of cutting conditions was used in FE simulations to predict cutting force, stresses and temperatures developed at around the edge of tool. The material cutting speed ranges were set between 20 and 250 m min-1. The rotary tool speed were 0 and 100 rpm.. The feed rate and the depth of cut were set constant. Simulation results provided the predicted cutting distribution of temperatures and stresses at the chip and work piece.

Assessment of Restricted Contact Cutting Tool in Dry Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Xianchen Ge ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Alpha Angle ◽  
Cutting Tools ◽  
Rake Face ◽  
Edge Radius ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper studies the performance of restricted cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using finite element simulations. The rake face of cemented carbide (WC/Co) cutting inserts is designed and the rake face length is shortened. The purpose is to examine the effect of shortened tools on machining performance and to compare it with regular cutting tools. The following restricted tool parameters are examined: length of rake face, alpha angle (the angle between the rake face and the supporting face), and edge radius. Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that restricted cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The length of rake face, the angle between the rake face and the supporting face, and edge radius all have influence on cutting force in their own ways. The effects of these three parameters on the tool temperature distribution are also investigated.

Tribology of Coated Tools in High-Speed Machining: A Tool Wear and “Equivalent Toolface” Geometry Based Study

2005 ◽  
Author(s):  
A. K. Balaji
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Tool Geometry ◽  
Machining Processes ◽  
Coated Tools ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Rough Turning

Predicting tool-wear (and thereby, tool-life) and selecting proper coated tools along with appropriate tool geometry still remains a major concern for industries trying to achieve increased productivity using automated machining processes. This study is focused upon aggressive high-speed rough turning of AISI 1045 steel. The wear patterns in different coated tools (one mono-layer PVD and two multi-layer CVD coatings) are correlated to changes in nominal tool geometry. This study focuses on the role of tooling geometry (inclination and rake angles) and their importance in dictating the behavior, performance, and wear of coated tools. Using an ‘equivalent toolface’ (ET) model, this study correlates the nominal tool geometry to an equivalent geometry, thereby introducing a new methodology for characterizing the complex effects of multilayer coatings in terms of simple effective tool geometry. The ET approach provides a new angle for understanding the tribological effects of coatings in machining.

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