Finite Element Analysis of the Influence of Cutting Edge Radius on Mechanical-Thermal Distribution in High-Speed Cutting TiAl6v4

2010 ◽  
Vol 458 ◽  
pp. 295-300
Author(s):  
Yi Hang Fan ◽  
Min Li Zheng ◽  
Shu Cai Yang ◽  
Wei Zhang ◽  
De Qiang Zhang
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Equivalent Stress ◽  
Cutting Edge ◽  
Plastic Deformation Zone ◽  
Edge Structure ◽  
High Speed Cutting ◽  
Cutting Edge Radius ◽  
Thermal Distribution ◽  
Edge Radius

On the basis of analyzing the cutting edge structure and cutting edge radius measurement of high-speed insert, thermal - mechanical coupling finite element method (FEM) is used in this paper, to obtain the effect law of different cutting edge radius on the mechanical-thermal distribution of high-speed cutting TiAl6V4. At last, cutting experiments are carried out to verify FEM results. There is a clear exposition of the intrinsic reason why the cutting edge radius has influence on the mechanical -thermal distribution of high-speed cutting process. The results indicate that the experimental results have a good agreement with FEM; with the cutting edge radius increases, cutting force increases; cutting temperature is not monotonic, but there exists an optimum edge radius that makes temperature lowest; cutting edge changes the plastic flow of materials around tool tip and broaden plastic deformation zone. The cutting edge radius has a greater impact on equivalent stress.

Influences of Cutting Edge Radius on Cutting Deformation in High-Speed Machining Ti6Al4V

2011 ◽  
Vol 305 ◽  
pp. 47-52
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan ◽  
De Qiang Zhang ◽  
Ying Bin Li
Keyword(s):  
High Speed ◽  
Equivalent Stress ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Cutting Edge ◽  
High Speed Machining ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Cutting Deformation ◽  
Deformation Coefficient

In order to obtain the influences of cutting edge radius on cutting deformation in high-speed machining Ti6Al4V, cutting temperature, equivalent stress distribution, the chip morphology and cutting deformation coefficient were analyzed in this paper. The results indicated that cutting edge changed the plastic flow of materials around tool tip and the actual tool rake angle, the tool-workpiece and tool-chip contact in cutting process which causes a greater impact on physical and mechanical performance in the given cutting conditions. When the cutting edge radius reached to 0.04mm,the cutting temperature and the equivalent stress existed mutations, which causes the mutation of chips. There was a chip thinning effect with the increase of the cutting edge radius. As the cutting edge radius increased, chip thickness and shear angle decreased, cutting deformation coefficient increased.

A Finite Element Analysis of Micro/Meso-Scale Machining Considering the Cutting Edge Radius

2007 ◽  
Vol 10-12 ◽  
pp. 631-636 ◽  
Author(s):  
Zi Yang Cao ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Finite Element ◽  
Stress Field ◽  
Size Effect ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Process ◽  
Plastic Deformation Zone ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Meso Scale

In order to investigate the effects of cutting edge radius on micro/meso-scale cutting process, the current paper is concerned with a fundamental investigation of the contribution of cutting edge radius to cutting temperature, stress field and size effect by means of two-dimensional finite-element simulation for orthogonal cutting process. The results indicated that cutting edge radius has remarkable effects on cutting temperature and stress field, and the existence of cutting edge radius is one of the main reasons generating size effect. The cutting edge radius affects the micro/meso scale cutting process at smaller uncut chip thickness by altering the effective rake angle and enhancing the plowing effect, affecting the material deformation process, expanding and widening the plastic deformation zone, and causing higher energy dissipation due to increased tool-chip contact length.

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.

Wear of High Speed Steel Bi-Metal Bandsaw Blade when Cutting AvestaPolarit 17-7 Stainless Steel in the As-Cast State

2004 ◽  
Vol 471-472 ◽  
pp. 431-437 ◽  
Author(s):  
Mohammed Sarwar ◽  
M. Persson ◽  
H. Hellbergh
Keyword(s):  
Stainless Steel ◽  
Steady State ◽  
High Speed ◽  
Adhesive Wear ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Flank Surface ◽  
Wear Modes

This paper reports experimental data on the wear of high-speed steel bimetal bandsaw blades cutting austenitic 17-7 stainless steel bars. Several different methods of assessing the wear modes and mechanisms are evaluated; Cutting and thrust force components, Set width, Kerf width, “Out-of-square” cutting, Wear modes and mechanisms and Chip characteristics. The wear mode established in the current work when bandsawing austenitic stainless steel with a bimetal blade is flank and corner wear together with formation of a cutting edge radius. The cutting edge radius increases as the wear progresses, reaching 25-50 mm after 300 cut sections. The established wear mechanism for the initial stages of wear is mild adhesive wear of the flank surface together with built-up edge formation and break-down. As the wear reaches steady-state the mechanism is adhesive wear of the flank surface with tempering/softening of high-speed steel layers. When the wear reached the steady-state region the level of thrust and cutting force were equal and relatively high. The kerf width appears to be less than the total set width of the blade, meaning that there is compression of the set teeth as they pass through the kerf. There is segmented chip formation with an increasing amount of vibration as the teeth wear, probably due to the increasing size of cutting edge radius. This work should be of great interest to the tool designer and user associated with bandsaws.

Research on Cutting Performances of Tool Rounded Cutting Edge in High Speed Milling Hardened Steel

2011 ◽  
Vol 188 ◽  
pp. 139-144
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan ◽  
W. Xu
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Simulation Models ◽  
Hardened Steel ◽  
Cutting Edge ◽  
High Speed Milling ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Simulation Results

Simulation models of both dynamic cutting forces and cutting temperatures considering effects of tool rounded cutting edge are established based on analysis of the influences of rounded cutting edge on high speed milling process. Influence law of tool rounded cutting edge radius on force and heat distribution in high speed milling hardened steel has been obtained according to the simulation results and also the simulation results have been verified by experiments. The results indicate that dynamic performances of high speed milling cutter in cutting hardened steel are directly influenced by rounded cutting edge radius, and the cutting forces fluctuated greatly with the variation of rounded cutting edge radius. Variations of rounded cutting edge radius have greater impact on cutting temperatures when the rounded cutting edge radius is less than 40μm. Cutting temperature rise slowly with the increase of rounded cutting edge radius when the rounded cutting edge radiuses are larger than 40μm. Simulation can precisely predict cutting temperatures and cutting forces considering influences of rounded cutting edge radius. Rounded cutting edge radius should be kept around 40~45μm for optimal cutting performances according to its influences on cutting forces and cutting temperatures in high speed milling hardened steel.

Effect of Rounded Cutting Edge Radius on Residual Stress within Machined Sublayer

2006 ◽  
Vol 532-533 ◽  
pp. 536-539
Author(s):  
Wen Jun Deng ◽  
Yong Tang ◽  
Wei Xia ◽  
Zhen Ping Wan
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Cutting Edge Radius ◽  
Edge Radius

A coupled thermal-mechanical model of plane-strain orthogonal metal cutting with continuous chip formation is developed to investigate the residual stresses in the finished workpiece. Deformation of the workpiece material is treated as elastic-viscoplastic with isotropic strain hardening, and the numerical solution accounts for coupling between plastic deformation and the temperature field, including treatment of temperature-dependent material properties. Automatic continuous remeshing and adaptive meshing technique are employed to achieve chip separation at the tool tip region and a satisfactory solution. The finite element model is well validated by comparing values of the predicted cutting forces and residual stresses with experimental results. Based on the established finite element model, the effect of rounded cutting edge radius on residual stress distribution is analyzed. The results show that altered cutting edge radius clearly produced significant changes in residual stresses. The maximum tensile residual stress and its penetration depth decrease as the cutting edge radius increases.

The Effect of Electrolytic Strengthening Treatment on Tap’s Service Life

2016 ◽  
Vol 693 ◽  
pp. 944-951
Author(s):  
Zhi Yang Feng ◽  
Xian Guo Yan ◽  
Yan Wen Lv ◽  
Hong Guo ◽  
Hang Fu ◽  
...  
Keyword(s):  
Service Life ◽  
Theoretical Basis ◽  
High Speed ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Experimental Results ◽  
Cutting Edge Radius ◽  
Edge Radius

In this study High-speed steel taps are taken as the research object. Electrolysis technology was used to deal with the taps in various count time (7s 14s 21s 28s 35s) and then obtain the corresponding radii of the cutting edge (11.38μm 15.05μm 20.35μm 23.00μm 25.55μm). The experimental results exhibit quantitatively the effect of tool radius on the performance of tapping. A radius on the cutting edge prevents fast and unpredictable wear. Moreover, the existence of an optimum value of the radius has been revealed experimentally. Tapping test is used to prove the optimal cutting edge radius is 15.05μm and the taps life increase about 2.5 times than usual taps. It can provide an important theoretical basis for the modifications of the cutting edge radius and give a method to improve tap life.

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