Machinability Study Using Chip Thickness Ratio on Difficult to Cut Metals by CBN Cutting Tool

2012 ◽  
Vol 504-506 ◽  
pp. 1317-1322 ◽  
Author(s):  
Sivaprakasam Thamizhmanii ◽  
Hasan Sulaiman
Keyword(s):  
Stainless Steel ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cubic Boron Nitride ◽  
Chip Thickness ◽  
Shear Angle ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Alloy Steels

Machinability is the one of the criteria in determining the life of the cutting tool. In this experiment, hard and difficult to cut materials like hard AISI 440 C stainless steel and hard SCM 440 alloy steels were discussed. However, machinability of the material is considered to be poor due to its inherent characteristics. The machinability studies on AISI 440 C stainless steel and SCM 440 alloy steels had not been carried out by researchers. Machinability indices used in such cases have the characteristics such as cutting force, surface roughness, tool wear etc. In the case of high-speed machining of said materials machinability indices such as chip thickness (RC), shear angle (Ф), surface integrity, and chip analysis are of prime importance. Most of the researchers have not given due consideration to these vital machinability indices necessary for understanding of high-speed cutting of said materials. In this work, an experimental investigation was carried out to understand the behavior of difficult to cut materials, when machined with Cubic Boron Nitride (CBN) insert tool. The results and analysis of this work indicated that the above-mentioned machinability indices are important and necessary to assess the machinability of said materials effectively. The operating parameters used were cutting velocity 100, 125, 150, 175 and 200 m/min with feed rate of 0.10, 0.20 and 0.30 mm rev-1 with constant depth of cut of 1.0 mm. The length of turning was 150 mm and 300 mm. Machinability of both materials and tool was evaluated in terms of roughness, flank wear, cutting force, chip thickness ratio and shear angle.

scholarly journals Neural Network Modeling of Cutting Force and Chip Thickness Ratio for Turning Aluminum Alloy 7075-T6

2018 ◽  
Vol 14 (1) ◽  
pp. 67-76
Author(s):  
Mohanned Mohammed H. AL-Khafaji
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Feed Force ◽  
Machining Force ◽  
Force Components

The turning process has various factors, which affecting machinability and should be investigated. These are surface roughness, tool life, power consumption, cutting temperature, machining force components, tool wear, and chip thickness ratio. These factors made the process nonlinear and complicated. This work aims to build neural network models to correlate the cutting parameters, namely cutting speed, depth of cut and feed rate, to the machining force and chip thickness ratio. The turning process was performed on high strength aluminum alloy 7075-T6. Three radial basis neural networks are constructed for cutting force, passive force, and feed force. In addition, a radial basis network is constructed to model the chip thickness ratio. The inputs to all networks are cutting speed, depth of cut, and feed rate. All networks performances (outputs) for all machining force components (cutting force, passive force and feed force) showed perfect match with the experimental data and the calculated correlation coefficients were equal to one. The built network for the chip thickness ratio is giving correlation coefficient equal one too, when its output compared with the experimental results. These networks (models) are used to optimize the cutting parameters that produce the lowest machining force and chip thickness ratio. The models showed that the optimum machining force was (240.46 N) which can be produced when the cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.27 mm/rev). The proposed network for the chip thickness ratio showed that the minimum chip thickness is (1.21), which is at cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.17 mm/rev).

Analytical Modeling of Chip Geometry in High-Speed Ball-End Milling on Inclined Inconel-718 Workpieces

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
End Milling ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Shear Angle ◽  
Analytical Models ◽  
Ball End Milling ◽  
Cutting Mechanisms ◽  
Chip Geometry

Most often contoured surfaces inclined at several inclinations are generated using ball-end milling of aerospace and automobile components. It is understood that the chip morphology and the corresponding cutting mechanisms change with a change in the tool-workpiece interactions on inclined surfaces. Analytical predictive models to accurately evaluate the undeformed and deformed geometries of chip in ball-end milling are not available. Therefore, this work presents development of analytical models to predict the cutting tool-workpiece interaction as the workpiece inclination changes, in terms of undeformed and deformed chip cross sections. The models further evaluate instantaneous shear angle along any cross section of the tool-work interaction on a ball-end cutter in a milling operation. The models illustrate evaluation of a chip segment and mechanism of its formation in ball-end milling on an inclined work surface. It is observed that the chip dimensions, except deformed chip thickness, increase with an increase in the workpiece inclination angle. Also, a higher workpiece inclination results into an easy flow of the deformed chip over the cutting tool flank, which leads to a higher shear angle during the cut. The predictive chip geometry models corroborate 90% to the experimental results obtained at various workpiece inclinations.

scholarly journals DEVELOPMENT OF FUZZY LOGIC MODEL FOR CUTTING PARAMETERS INFLUENCE ON THE CUTTING FORCE AND THE CHIP THICKNESS RATIO DURING TURNING OF ALUMINUM ALLOY 1350-O

2018 ◽  
Vol 18 (1) ◽  
pp. 110-124
Author(s):  
Mohanned H AL-Khafaji
Keyword(s):  
Fuzzy Logic ◽  
Cutting Force ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Logic Models ◽  
Machining Force ◽  
Force Components

In turning operation, numerous parameters are utilized to analyze machinability. Parameters,for instant, tool wear, tool life, cutting temperature, machining force components, powerconsumption, surface roughness, and chip thickness ratio are frequently utilized. The goal ofthis work is to model the effect of cutting parameters (cutting speed, depth of cut and feedrate) on the machining force and chip thickness ratio during turning ductile aluminum 1350-O. Four fuzzy logic models were built to model the relationship between cutting parametersand the three force components of machining force and the chip thickness ration. The inputsto all fuzzy logic models are cutting speed, depth of cut and feed rate. Whereas, the outputfor first, second, third and fourth models are cutting force, passive force, feed force and chipthickness ratio, respectively. All fuzzy models showed good match to the experimental dataand the computed correlation coefficients were larger than or equal 0.9998. Those modelswere used to optimize the cutting process and give the optimum cutting parameters.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

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.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

High-Speed Capturing of Stress Distribution of Workpiece under Ultrasonically Assisted Cutting Condition

2014 ◽  
Vol 1017 ◽  
pp. 747-752
Author(s):  
Hiromi Isobe ◽  
Keisuke Hara
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Light Emission ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Photoelastic Method ◽  
Intermittent Cutting ◽  
Ultrasonic Vibration Cutting

This paper reports the stress distribution inside the workpiece under ultrasonic vibration cutting (UVC) condition. Many researchers have reported the improvement of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVC condition. However general dynamometers have an insufficient frequency band to observe the processing phenomena caused by UVC. In this paper, stress distribution inside the workpiece during UVC was observed by combining the flash light emission synchronized with ultrasonically vibrating cutting tool and the photoelastic method. Instantaneous stress distribution during UVC condition was observed. Because UVC induced an intermittent cutting condition, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. It was found that instantaneous maximum cutting force during UVC condition was smaller than quasi-static cutting force during conventional cutting when the cutting speed was less than 500 mm/min.

The Ledge Tool: A New Cutting Tool Insert

1985 ◽  
Vol 107 (2) ◽  
pp. 99-106 ◽  
Author(s):  
R. Komanduri ◽  
M. Lee
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tool ◽  
Metal Removal ◽  
Face Milling ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Peripheral Milling ◽  
Cemented Carbide Tool ◽  
Edge Wear

The salient features of a simple, wear-tolerant cemented carbide tool are described. Results are presented for high-speed machining (3 to 5 times the conventional speeds) of titanium alloys in turning and face milling. This tool, termed the ledge cutting tool, has a thin (0.015 to 0.050 in.) ledge which overhangs a small distance (0.015 to 0.060 in.) equal to the depth of cut desired. Such a design permits only a limited amount of flank wear (determined by the thickness of the ledge) but continues to perform for a long period of time as a result of wear-back of the ledge. Under optimum conditions, the wear-back occurs predominantly by microchipping. Because of geometric restrictions, the ledge tool is applicable only to straight cuts in turning, facing, and boring, and to face milling and some peripheral milling. Also, the maximum depth of cut is somewhat limited by the ledge configuration. In turning, cutting time on titanium alloys can be as long as ≈ 30 min. or more, and metal removal of ≈ 60 in.3 can be achieved on a single edge. Wear-back rates in face milling are about 2 to 3 times higher than in straight turning. The higher rates are attributed here to the interrupted nature of cutting in milling. Use of a grade of cemented carbide (e.g., C1 Grade) which is too tough or has too thick a ledge for a given application leads to excessive forces which can cause gross chipping of the ledge (rapid wear) and/or excessive deflection of the cutting tool with reduced depth of cut. Selection of a proper grade of carbide (e.g., Grades C2, C3, C4) for a given application results in uniform, low wear-back caused by microchipping. Because of the end cutting edge angle (though small, ≈ 1 deg) used, the ledge tool can generate a slight taper on very long parts; hence an N.C. tool offset may be necessary to compensate for wear-back. The ledge tool is found to give excellent finish (1 to 3 μm) in both turning and face milling. In general, conventional tooling with slight modifications can be used for ledge machining. The ledge tool can also be used for machining cast iron at very high speeds.

Machining Capabilities of Abrasive Waterjet on Stainless Steel 304

2019 ◽  
Vol 895 ◽  
pp. 313-318
Author(s):  
S.B. Supriya ◽  
S. Srinivas
Keyword(s):  
Stainless Steel ◽  
Stainless Steels ◽  
Cutting Tool ◽  
High Hardness ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Sem Images ◽  
Enhanced Production ◽  
Work Material

Stainless Steels are possessing fabrication flexibility, high hardness, durability, low maintenance, high strength and resistance to heat and corrosion. This alloy steel is extensively used in various engineering applications. Some of the conventional machining techniques results in loss of original properties of stainless steel work material and makes it to behave like ordinary material within the machined surface. Machining of Stainless steels is more challenging due to its high alloying content. Problems such as application of huge coolant supply and poor chip breaking while machining, work hardening in work material, use of cutting tools with varying tool signature, results in enhanced production cost and time. Further, it is important to ensure that there is no machine tool-cutting tool vibration leading to edge chipping of cutting tool. To avoid all these problems, Abrasive water jet machining (AWJM) is used. This paper presents the machining capabilities of AWJ on Stainless Steel304. Influence of dynamic input parameters such as jet pressure, speed of traverse and abrasive flow rate on the depth of cut is investigated. An empirical model is proposed for depth of cut and an error analysis is done with measured and modeled values of depth of cut. It was found that traverse speed influences more than other parameters. SEM images indicated smooth surface at entrance and waviness at exit side. The model proposed predicts the depth of cut more or less accurately.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

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