Investigation for High Speed Ultrasonic Cutting of Aluminum Alloy

2012 ◽  
Vol 516 ◽  
pp. 367-372 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Yoshihiro Take ◽  
Toshihiko Koiwa
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Ultrasonic Oscillation ◽  
Workpiece Material ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Cemented Carbide Tool ◽  
Cutting Operation ◽  
Ultrasonic Cutting

This study investigated phenomena of ultrasonic cutting in the case of high-speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in the 1950s. He found a critical cutting speed that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high-speed cutting conditions because the effects of ultrasonic application are cancelled due to tool contacts with the workpiece during the cutting operation. Present ultrasonically assisted cutting cannot allow increased cutting speed because cutting speed is limited by a critical cutting speed that is less than that compared with general cutting speed. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high-speed ultrasonic cutting, and the maximum cutting speed in this research was 300 m/min which is higher than general critical cutting speed. The workpiece material was A5056 and cemented carbide tool inserts were employed in this research. Without ultrasonic oscillation, machined surface retained some built up edge and surface roughness is 28 μmRz. In the case of ultrasonic cutting, surface hasnt built up edge and periodically marks due to ultrasonic oscillation remained on the surface. The roughness of conventionally cut surface is better than in ultrasonic cutting. The cutting phenomena of ultrasonic cutting are different compared with those under conventional cutting conditions.

Investigation of Cutting Phenomena in High Speed Ultrasonic Turning

2012 ◽  
Vol 523-524 ◽  
pp. 209-214 ◽  
Author(s):  
Keisuke Hara ◽  
Daisuke Hashikai ◽  
Hiromi Isobe ◽  
Jun Ishimatsu ◽  
Yoshihiro Take ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Rake Face ◽  
Workpiece Material ◽  
High Speed Cutting ◽  
Cemented Carbide Tool ◽  
Cutting Operation ◽  
Low Amplitude ◽  
Ultrasonic Cutting

This study investigated phenomena of ultrasonic cutting in case of high speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in 1950’s. He found “critical cutting speed” that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high speed cutting conditions because the effects of ultrasonically applying are canceled due to tool contacts with workpiece during cutting operation. Present ultrasonically assisted cutting cannot increase cutting speed because cutting speed is limited by above reason. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high speed ultrasonic cutting, maximum cutting speed of this research was 160m/min which is higher than general critical cutting speed. Workpiece material is JIS SUS304 stainless steed and cemented carbide tool inserts were employed in this research. In ordinary cutting, generate terrible built up edge on to tool rake face. In case of low amplitude ultrasonic cutting, tool rake face hasn’t built up edge and periodically marks by ultrasonic oscillation were remained on the surface. Cutting phenomena of ultrasonic cutting is different compared with ordinary cutting conditions.

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

Influence of Work-Hardening on Wear Resistance of Machined Surface of Aviation Aluminum Alloy

2013 ◽  
Vol 589-590 ◽  
pp. 117-121 ◽  
Author(s):  
Xiu Li Fu ◽  
Zeng Hui An ◽  
Yang Qiao ◽  
Xiu Hua Men
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Micro Hardness ◽  
Machined Surface ◽  
And Performance

Work-hardening of machined surface plays an important role in the evaluation of surface quality and performance of wear resistance in the process of machining components. In this study work-hardening of machined surface during milling 7050-T7451 aluminum alloy is investigated using micro-hardness experiments under different cutting conditions. Moreover, the wear resistance of machined surface including wear quantity and friction coefficient are obtained and studied by means of high speed ring-block friction-wear tester. The work-hardening and wear resistance are particularly sensitive to cutting speed. Friction coefficient has marked drop trends and the tendency of wear quantity is ascend in first and descend at last as work-hardening increases. The comparison of wear resistance under different cutting conditions shows that the wear resistance of machined surface can be directly affected by work-hardening and machined surface obtained by high speed milling with higher micro-hardness have more superior in wear resistance performance.

Study on Residual Stress for High-Speed Cutting Titanium Alloy Based on Finite Element Method

2011 ◽  
Vol 188 ◽  
pp. 216-219 ◽  
Author(s):  
M.H. Wang ◽  
Zhong Hai Liu ◽  
Hu Jun Wang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Titanium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Simulation Method ◽  
Residual Tensile Stress ◽  
Cutting Depth ◽  
Machined Surface ◽  
High Speed Cutting

In order to improve machined surface quality and reduce the deformation, the residual stress involved in cutting titanium alloy was studied under different cutting speed and cutting depth by finite element simulation method. The results indicate that the increase of cutting speed and cutting depth are helpful to the surface residual compressive stress generating. However the increase of cutting speed also leads to the increase of surface residual tensile stress, the effect degree is relatively small. It is required to select higher cutting speed and smaller cutting depth to improve the surface stress state and reduce the unexpected distortion.

Contributions of High-Speed Cutting and High Rake Angle to the Cutting Performance of Natural Rubber

2014 ◽  
Vol 8 (4) ◽  
pp. 550-560 ◽  
Author(s):  
Naoki Takahashi ◽  
◽  
Jun Shinozuka
Keyword(s):  
Natural Rubber ◽  
Shear Zone ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Performance ◽  
Machined Surface ◽  
Shape Accuracy ◽  
High Speed Cutting

This study investigates the contributions of high-speed cutting and a high rake angle to the improvement of the cutting performance of natural rubber. Orthogonal cutting experiments were conducted at cutting speeds ranging from 1.0 m/s to 141.1 m/s. The rake angles examined were 0°, 20° and 50°. The following results were obtained from the experiments. The cutting ratio is almost 1.0 regardless of the cutting speed and rake angle. The cutting force rises rapidly as the cutting speed increases. High-speed cutting or a high rake angle eliminates tear defects on the machined surface and reduces chipping defects at the entry edge of the workpiece. An uncut portion, however, always remains at the exit edge. The cross-sectional shape of the machined surface becomes concave. Besides, the machined surface comes into broad contact with the clearance face. These degradations in the shape accuracy arise from the large elastic distortion that occurs in the shear zone. Increasing the cutting speed improves the flatness of the machined surface. Although an analysis of the cutting mechanism reveals that the apparent stiffness of the material in the shear zone is enhanced with increasing the cutting speed, a very high cutting speed worsens the shape accuracy because of the development of shock waves. Depending on the rake angle, there is a critical cutting speed that should not be exceeded to maximize the cutting performance of natural rubber.

Control and Mechanism Analysis of Serrated Chip Formation in High Speed Machining of Aluminum Alloy 7050-T7451

2020 ◽  
Vol 990 ◽  
pp. 13-17 ◽  
Author(s):  
Qi Hang Shi ◽  
Zong Cheng Hao ◽  
Shuai Wang ◽  
Xiu Li Fu ◽  
Hui Wang
Keyword(s):  
Aluminum Alloy ◽  
Chip Formation ◽  
High Speed ◽  
Morphological Evolution ◽  
Cutting Speed ◽  
Mechanism Analysis ◽  
Serrated Chip ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Cutting Speeds

Aluminum alloy 7050-T7451 is widely used in aeronautical large structural parts, and high speed cutting is often used in machining. The serrated chip is a critical state for chip formation in high speed cutting, and its formation and control mechanism are of great significance for actual machining. To study the chip formation of high speed cutting aluminum alloy 7050-T7451, the chips at different cutting speeds are obtained by high speed cutting experiments. Combined with microscopic observation, the chip shape evolution, chip localization fracture process and mechanism of different cutting speeds are analyzed. The morphological evolution of chips and the mechanism of chip breaking during high speed cutting of aluminum alloy are revealed. According to the machined surface of the chip root and the angle of the chip, the formation mechanism of the curl radius formed by the chip is analyzed. The critical cutting speed of plastic-brittle transformation of aluminum alloy 7050-T7451 in high speed cutting is obtained by studying the critical condition for strip-to-serration transition of chip morphology.

scholarly journals Experimental Investigation on the Cutting Mechanism of Oxygen Free Copper in Cutting Speeds Ranging from 1 m/s to 210 m/s

2013 ◽  
Vol 797 ◽  
pp. 208-213 ◽  
Author(s):  
Jun Shinozuka
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Shear Plane ◽  
Friction Angle ◽  
Temperature Fields ◽  
Cutting Mechanism ◽  
Machined Surface ◽  
High Speed Cutting

The orthogonal cutting tests of oxygen free copper with a cutting speed of from 1 m/s to 210 m/s were performed. The effect of the high-speed cutting on the improvement over the quality of the machined surface, which was evaluated by the thickness of the plastic flow layer and the surface roughness, was examined. By employing the simple shear plane model, the cutting mechanism was analyzed. The results were compared with the results for cutting of aluminum alloy obtained previously. For oxygen free copper, the resultant cutting force does not increase in high-speed cutting. However, the friction angle on the tool-chip interface rises clearly in high-speed cutting. This paper discusses the reason for the increase in the friction angle at the tool-chip interface by investigating the stress and temperature fields on the shear plane and the tool-chip interface.

Chip Flow and Scaling Laws in High Speed Metal Cutting

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Guy Sutter ◽  
Alain Molinari ◽  
Gautier List ◽  
Xuefeng Bi
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Scaling Laws ◽  
Scaling Law ◽  
Chip Morphology ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Workpiece Material ◽  
Machined Surface ◽  
Perfectly Plastic

Chip formation in machining plays an important role in the cutting process optimisation. Chip morphology often reflects the choice of cutting conditions, the tool wear and by consequences the integrity of the machined surface and tool life. In this study, photographs of the chip morphology during high speed machining of a middle hard steel (C20 similar to AISI 1020) are taken by using a ballistic setup. From these recordings, the evolution of the chip morphology is presented and analysed in terms of cutting conditions. A simplified modeling is then proposed by considering the workpiece material as elastic perfectly plastic. The existence of a scaling law governing the chip morphology in high speed machining is demonstrated. The cutting velocity is shown to have a weak effect at high speed machining as opposed to the well known strong influence of the velocity in the range of low cutting speeds.

Study on the Coated Tool Disability and the Work-Piece Surface Quality in High Speed Cutting

2010 ◽  
Vol 431-432 ◽  
pp. 397-400 ◽  
Author(s):  
Jin Xu
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
Cutting Speed ◽  
Work Piece ◽  
Machined Surface ◽  
Workpiece Surface ◽  
High Speed Cutting ◽  
Coated Tool ◽  
Tool Cutting ◽  
Experimental Researches

The results of the experimental researches show that the high speed cutting tool is disabled in two modes of gradual wear and rapid breakage as HSC proceeds. Tool breakage occurs in low speed cutting. In process of HSC, the tool disability is the combination of flank face wear, boundary wear and cutting edge slope-plane wear. Under the action of the tool cutting movement, the ridges and furrows and burntthrough speckles and the molten metal daub phenomena come into being on the machined surface. With cutting speed increasing, it is weakened that tool wear has adverse effects on the forming of machined surface, and the workpiece surface quality is improved to a certain extent.

Effects of Cooling Conditions on Thermal Crack Initiation of Brittle Cutting Tools during Intermittent Cutting

2015 ◽  
Vol 656-657 ◽  
pp. 237-242
Author(s):  
Kenji Yamaguchi ◽  
Tsuyoshi Fujita ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
Mitsugu Yamaguchi ◽  
...  
Keyword(s):  
Crack Initiation ◽  
Thermal Shock ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Thermal Crack ◽  
Cooling Conditions ◽  
Cutting Operation ◽  
Intermittent Cutting

It is well known that a series of cracks running perpendicular to the cutting edge are sometimes formed on the rake face of brittle cutting tools during intermittent cutting. The cutting tool is exposed to elevated temperatures during the periods of cutting and is cooled quickly during noncutting times. It has been suggested that repeated thermal shocks to the tool during intermittent cutting generate thermal fatigue and result in the observed thermal cracks. Recently, a high speed machining technique has attracted attention. The tool temperature during the period of cutting corresponds to the cutting speed. In addition, the cooling and lubricating conditions affect the tool temperature during noncutting times. The thermal shock applied to the tool increases with increasing cutting speed and cooling conditions. Therefore, to achieve high-speed cutting, the evaluation of the thermal shock and thermal crack resistance of the cutting tool is important. In this study, as a basis for improving the thermal shock resistance of brittle cutting tools during high-speed intermittent cutting from the viewpoint of cutting conditions, we focused on the cooling conditions of the cutting operation. An experimental study was conducted to examine the effects of noncutting time on thermal crack initiation. Thermal crack initiation was found to be restrained by reducing the noncutting time. In the turning experiments, when the noncutting time was less than 10 ms, thermal crack initiation was remarkably decreased even for a cutting speed of 500 m/min. In the milling operation, the number of cutting cycles before thermal crack initiation decreased with increasing cutting speed under conditions where the cutting speed was less than 500 m/min. However, when the cutting speed was greater than 600 m/min, thermal crack initiation was restrained. We applied the minimal quantity lubrication (MQL) coolant supply to the intermittent cutting operation. The experimental results showed that the MQL diminished tool wear compared with that under the dry cutting condition and inhibited thermal crack initiation compared with that under the wet cutting condition.

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