Effect of Cutting Edge Roundness on Work Hardened Surface Layer in Metal Cutting

2009 ◽  
Vol 407-408 ◽  
pp. 440-443
Author(s):  
Rikio Hikiji ◽  
Eiji Kondo ◽  
Minoru Arai
Keyword(s):  
Surface Layer ◽  
Surface Integrity ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Precision Machining ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Ultra Precision ◽  
Machined Surface Integrity ◽  
Hardened Surface

In the ultra-precision machining, the smaller the undeformed chip thickness is, the more the machined surface integrity is affected by the cutting edge roundness of the cutting tool. In this research, the work hardened surface layer was dealt with as an evaluation of the machined surface integrity and the effect of the mechanical factors on work hardening was investigated experimentally in orthogonal cutting. In the case of a rounded cutting edge, unlike a sharp one, it makes the generation mechanism of the work hardened surface layer complicated. In this research, the mechanical dominant factors were investigated by comparing the effect of the rounded cutting edge on the work hardened surface layer, which counts for much in ultra precision machining involved in small undeformed chip thickness, with that of the sharp cutting edge.

Influence of Scratch Marks on Undeformed Chip Thickness in Ultra-Precision Cutting of Al-Mg Alloys

2017 ◽  
Vol 749 ◽  
pp. 27-32
Author(s):  
Keisuke Amaki ◽  
Yukio Maeda ◽  
Tomohiro Iida ◽  
Kazuya Kato ◽  
Hideaki Tanaka ◽  
...  
Keyword(s):  
High Efficiency ◽  
Surface Defects ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Mg Alloy ◽  
Glassy Material ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Laser Printers ◽  
Ultra Precision

Recently, high efficiency and performance have become necessary attributes of information equipment such as laser printers. Thus, demand has increased for optical scanning parts that reduce optical aberration, scatter, and diffraction are required in laser printers. Polygon mirrors are manufactured by polishing a plating or glassy material to a mirror finish. In this study, we shortened the manufacturing process to improve the productivity and ultra-precision cutting technology of polygon mirrors made of aluminum. Thus, we had to reduce the geometric surface roughness achieved by mirror-cutting Al-Mg alloy and remove tear-out and scratch marks that occur during the cutting process. We investigated the cutting edge shape by using a straight diamond tool to decrease the surface defects produced during the ultra-precision cutting of Al-Mg alloy. We examined the mechanism for the occurrence of scratch marks and a method to reduce them. First, we measured the shape of the scratch marks and the cross-section with a scanning electron microscope. We found the tool collides with crystallization to produce small pieces, which then cause scratch marks. We developed a triple-facet tool with a double-facet at the end cutting edge to remove scratch marks and investigated the influence of surface defects. We clarified that using the triple-facet for a tool setting angle of 0° to 0.04° could achieve a good-quality machined surface without tear-out and scratch marks. In addition, the undeformed chip thickness was less than 80 nm

Experimental Investigation of Turning with Magnetized Cutting Emulsion

2010 ◽  
Vol 426-427 ◽  
pp. 225-229
Author(s):  
Jun Zhou ◽  
Rong Di Han
Keyword(s):  
Experimental Investigation ◽  
Cutting Force ◽  
Surface Integrity ◽  
Compression Ratio ◽  
Chip Thickness ◽  
Turning Process ◽  
Machined Surface ◽  
Dry Turning ◽  
Machined Surface Integrity

The purpose of this study is to clarify the possibility of the turning process with the magnetized cutting emulsion. In particular, the effect of the magnetized cutting emulsion in turning process were examined through observation and measurement of the shape of the generated chips, machined surface integrity, cutting force and chip thickness compression ratio in a series of turning experiments. As a result, compared with dry turning and turning with cutting emulsion, the application of the magnetized cutting emulsion can decrease cutting force and chip thickness compression ratio, increases machined surface integrity.

Metal Turning Mechanical Model of Machined Surface Roughness

2015 ◽  
Vol 1095 ◽  
pp. 770-772 ◽  
Author(s):  
Quan Li ◽  
Man Chen Xiong ◽  
Yin Yin Liu
Keyword(s):  
Surface Roughness ◽  
Mechanical Model ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Machined Surface Roughness

Consider the mechanism of the formation of surface roughness, this paper establish the mechanical model of undeformed chip thickness caused by the cutting edge,and the mechanical model of cutting residues caused by the tool feed movement . By means of Brammertz equation, combining the above two mechanical model,a more perfect surface roughness mechanical mode is established.

Characterization of Cutting-Induced Heat Generation in Ultra-Precision Milling of Aluminium Alloy 6061

2013 ◽  
Vol 552 ◽  
pp. 201-206
Author(s):  
Su Juan Wang ◽  
Suet To ◽  
Xin Du Chen
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Heat Generation ◽  
Feed Rate ◽  
Dimensional Accuracy ◽  
Precision Machining ◽  
Machined Surface ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Alloy 6061

The technology of ultra-precision machining with single crystal diamond tool produces advanced components with higher dimensional accuracy and better surface quality. The cutting-induced heat results in high temperature and stress at the chip-tool and tool-workpiece interfaces therefore affects the materials and the cutting tool as well as the surface quality. In the ultra-precision machining of al6061, the cutting-induced heat generates precipitates on the machined surface and those precipitates induce imperfections on the machined surface. This paper uses the time-temperature-precipitation characteristics of aluminum alloy 6061 (al6061) to investigate the effect of feed rate on the cutting-induced heat generation in ultra-precision multi-axis milling process. The effect of feed rate and feed direction on the generation of precipitates and surface roughness in ultra-precision raster milling (UPRM) is studied. Experimental results show that heat generation in horizontal cutting is less than that in vertical cutting and a larger feed rate generates more heat on the machined workpiece. A smaller feed rate produces a better surface finish and under a larger feed rate, scratch marks are produced by the generated precipitates and increase surface roughness.

A Comparison of the Simulated Dynamics of Various Models Used to Predict Undeformed Chip Thickness in High-Speed Low-Radial-Immersion Milling Processes

2013 ◽  
Author(s):  
Josiah A. Bryan ◽  
Roger C. Fales
Keyword(s):  
High Speed ◽  
Chip Thickness ◽  
Milling Process ◽  
Precision Machining ◽  
Traditional Model ◽  
Cnc Milling ◽  
Undeformed Chip Thickness ◽  
Milling Tool ◽  
Tool Damage ◽  
Low Radial Immersion

Various models have been proposed to estimate the undeformed thickness of chips produced by a CNC milling tool, in order to calculate the forces acting on the tool. The choice of model significantly affects the simulated dynamics of the tool, thereby affecting the dynamic stability of the simulated process and whether or not chatter occurs in a given cutting scenario. Simulations of the dynamics of the milling process can be used to determine the conditions at which chatter occurs, which can lead to poor surface finish and tool damage. The dynamics of a traditional model and a more detailed numerical model are simulated here with particular emphasis on the differences in their chatter bifurcation points. High-speed, low-radial-immersion milling processes are simulated because of their application in industrial high-precision machining.

scholarly journals Micro-machining

2012 ◽  
Vol 370 (1973) ◽  
pp. 3973-3992 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
Werner Preuss
Keyword(s):  
Surface Properties ◽  
Continuum Mechanics ◽  
Surface Integrity ◽  
Bulk Material ◽  
Atomic Level ◽  
Precision Machining ◽  
Micro Machining ◽  
Precision Engineering ◽  
Left Behind ◽  
Ultra Precision

Manipulating bulk material at the atomic level is considered to be the domain of physics, chemistry and nanotechnology. However, precision engineering, especially micro-machining, has become a powerful tool for controlling the surface properties and sub-surface integrity of the optical, electronic and mechanical functional parts in a regime where continuum mechanics is left behind and the quantum nature of matter comes into play. The surprising subtlety of micro-machining results from the extraordinary precision of tools, machines and controls expanding into the nanometre range—a hundred times more precise than the wavelength of light. In this paper, we will outline the development of precision engineering, highlight modern achievements of ultra-precision machining and discuss the necessity of a deeper physical understanding of micro-machining.

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