scholarly journals Effect of Cutting Parameters on Tool-Chip Interface Temperature in an Orthogonal Turning Process

2014 ◽  
Vol 903 ◽  
pp. 21-26 ◽  
Author(s):  
Shamsuddin Sulaiman ◽  
Amir Roshan ◽  
Soroosh Borazjani
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Interface Temperature ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The aim of this paper is to investigate the effect of cutting speed and uncut chip thickness on cutting performance. A Finite Element Method (FEM) based on the ABAQUS explicit software which involves Johnson-Cook material mode and Coulombs friction law was used to simulate of High Speed Machining (HSM) of AISI 1045 steel. In this simulation work, feed rate ranging from 0.05 mm/rev to 0.13 mm/rev and cutting speed ranging from 200 m/min to 600 m/min at three different cutting speeds were investigated. From the simulation results it was observed that increasing feed rate and cutting speed lead to increase temperature and stress distribution at tool/chip interface. The results obtained from this study are highly essential to predict machining induced residual stresses and thermo-mechanical deformation related properties on the machined surface.

Experimental Study on Wear-Resistance of Machined Surface in High Speed Milling Aviation Aluminum Alloy

2012 ◽  
Vol 500 ◽  
pp. 117-122
Author(s):  
Xiu Li Fu ◽  
Xiao Qin Wang ◽  
Yong Zhi Pan ◽  
Yang Qiao
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Surface Quality ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Resistance Performance

The wear-resistance performance of machined surface is an important factor in the evaluation of surface quality and precision in aerospace manufacturing industry. By using high-speed Ring-Block friction and wear machine (MRH-3), the influence of cutting parameters in milling aluminum alloy 7050-T7451 on wear-resistance of machined surface including friction coefficient and wear quantity are experimentally investigated. The wear-resistance is particularly sensitive to cutting speed and feed rate. The friction coefficient has marked drop trends as cutting speed increases. The influence of cutting speed on wear quantity is more complicated and the tendency of wear quantity was ascend in first and descend at last (v>900/min). The results show that the influence of cutting parameters on wear-resistance was also positively correlated with surface roughness and work-hardening of machined surface. The high work-hardening and surface quality had the promoting effecting on wear-resistance. The experiment and analysis results show that the machined surface by high speed cutting and lower feed rate has more superior in surface quality and wear-resistance performance comparing with conventional cutting speed.

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.

Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

Prediction of the Surface Roughness in High-Speed Machining Based on Molecular-Mechanical Theory of Friction

2011 ◽  
Vol 308-310 ◽  
pp. 1134-1138 ◽  
Author(s):  
Su Yu Wang ◽  
Wen Chao Wang ◽  
Tao Yu ◽  
Bin Jiang
Keyword(s):  
Surface Roughness ◽  
Flow Stress ◽  
Mechanical Model ◽  
High Speed ◽  
High Speed Machining ◽  
Mechanical Theory ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Surface roughness is an important parameter to evaluate the quality of high-speed machining (HSM). This paper establishes a mechanical model based on the molecular-mechanical theory of friction to study factors that influence the surface roughness in HSM. The relationship between flow stress and the remnant height on the machined surface is obtained. The HSM process of AISI-1045 steel is simulated by using finite element method (FEM) based on DEFORM-2D and the flow stress is obtained. The surface roughness of workpiece machined by HSM is calculated based on the value of flow stress and the mechanical model. The result shows that the surface roughness of workpiece in HSM is acceptable, and the mechanical model supplies a method to study the surface roughness in HSM.

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.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

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