A Fractal Analysis of Cutting Force in Simulation and Experiment

2013 ◽  
Vol 589-590 ◽  
pp. 122-127 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xin Yu Song ◽  
Xiang Cheng
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Fractal Analysis ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Practical Implementation ◽  
Mechanical Coupling

A 3D finite element model (FEM) of metal cutting was constructed based on the thermal-mechanical coupling theory. The cutting process of Sialon ceramic tools turning Inconel 718 was simulated and experimented. The effect of cutting speed, feed rate and depth of cut on the cutting force was analyzed. According to the correlation characteristics between the data points, the fractal characteristics of cutting forces in the cutting process were also investigated. The results showed that the cutting speed had a great effect on the fractal dimension of cutting force. The simulation results were in good agreement with the experimental findings. It was concluded that the minimum fractal dimension of cutting force was obtained at v=230 m/min under these experiment conditions. The fractal analysis is a simple and powerful tool for quantifying the stability of cutting process. The finding of this research is valuable for future practical implementation.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

Computational of Orthogonal Metal Cutting Process Using Smooth Particle Hydrodynamics

2017 ◽  
Vol 867 ◽  
pp. 119-126
Author(s):  
S. Muthusamy ◽  
A Arulmurugu
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Smooth Particle Hydrodynamics ◽  
Particle Hydrodynamics ◽  
Sph Model

In modern years, simulating metal cutting process used in Finite element method (FEM). The cutting force is used to identify the excessive friction of machining interface and worn out tool. Optimization of machining parameters are used to maintain the precision of the component, power consumption minimized and tool wear reduced. The current project presents the simulated Finite Element SPH Model used for predict the cutting force and associate with experimental confirmation while turning the AA2219-TiB2/ZrB2 metal matrix composites (MMC). Smooth Particle Hydrodynamics (SPH) machining simulation was carried out using a Lagrangian finite element based machining model to predict the cutting force. The turning simulation operation carried out using ANSYS AUTODYN (SPH) software. Machining parameters are cutting speed, feed rate and depth of cut. The results predicted from the SPH analysis virtually close to the results attained from the experimental work. Simulation of machining test using SPH model is preferred over actual cutting test because of it reduce cost and time.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Cutting Characteristics of Sugarcane in Terms of Physical and Chemical Properties

2020 ◽  
Vol 63 (4) ◽  
pp. 1007-1017
Author(s):  
Luxin Xie ◽  
Jun Wang ◽  
Shaoming Cheng ◽  
Dongdong Du
Keyword(s):  
Finite Element ◽  
Chemical Composition ◽  
Correlation Analysis ◽  
Finite Element Model ◽  
Physical Properties ◽  
Cutting Force ◽  
Single Point ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process

HighlightsThe cutting mechanism of sugarcane stalks using single-point clamping was analyzed.Physical properties, chemical composition, and maximum cutting force of sugarcane were explored.Strong and complicated correlations between physical properties and chemical composition were established.Stress distributions in sugarcane stalks and the cutting blade were predicted using a finite element model.Abstract. Research on the cutting characteristics of sugarcane stalks is of great significance to improve harvest mechanization. In this study, perpendicular cutting of sugarcane stalks at six different nodes and internodes along the stalk was tested using a single-point clamping method at three cutting speeds (30, 40, and 50 mm min-1). The physical properties and chemical composition were also measured. At the 50 mm min-1 cutting speed, the maximum cutting forces at nodes and internodes upward along the stalk decreased gradually from 810 to 530 N and from 600 to 440 N, respectively. The maximum cutting force was positively correlated with the cutting speed at the same position. Differences in the microstructures of nodes, internodes, and epidermis were revealed by SEM micrographs. The physical properties and chemical composition of the stalks showed significant correlations. Correlation analysis was used to clarify the complicated interrelationships among these independent variables and revealed the interacting mechanism between physical properties and chemical composition. A finite element model was established to simulate the sugarcane cutting process. Results showed that the simulated cutting resistance of the blade was close to that in the experiments. The maximum Von Mises stress of the sugarcane stalk and blade in the cutting process were about 23.34 and 254.17 MPa, respectively. The results of this study provide guidance for designing and optimizing base-cutters of sugarcane harvesters and similar cutting equipment. Keywords: Chemical composition, Correlation analysis, Cutting characteristics, Microstructure, Physical properties, Simulation.

A Research on the SiCp Reinforcing Cu-Base Composite Material's Cutting Performance

2011 ◽  
Vol 175 ◽  
pp. 116-120
Author(s):  
Yi Ping Zhang ◽  
Yi Yi Tao ◽  
Zuo Jiang
Keyword(s):  
Composite Material ◽  
Electron Microscope ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Dislocation Theory ◽  
Cutting Surface ◽  
Base Composite ◽  
Electron Microscope Analysis

The relationships among the n, ap , and f of the SiCp /Cu composite material produced by powder metallurgy and extrusion have been investigated. The cutting force F of this material is also discussed in this paper by the measuring of the three cutting factors of n, ap, and f, applying the dislocation theory and the electron microscope analysis of the cutting surface and sub-surface. The differences are analyzed between the SiCp/Cu composite materials, QSn6-6-3. H59-1and the copper cutting surface and the sub-surface. The forming of mechanism, the function of SiCp in the cutting process and the influence on the cutting surface quality are also analyzed. This research has shown: because the SiCp particles prevent the dislocation moving, the dislocation groups are formed on the SiC/Cu interface, and the stress concentration is produced, the typical brittle separation appears in the SiC/Cu composite material cutting process. In addition, the cutting force increases with the depth of cut and feed increasing and decreases while the cutting speed increases.

scholarly journals MODELLING OF RESPONSES FROM ORTHOGONAL METAL CUTTING OF MILD STEEL USING CARBIDE INSERT TOOL

2016 ◽  
Vol 36 (1) ◽  
pp. 96-109
Author(s):  
MK Onifade ◽  
AC Igboanugo ◽  
JO Osarenmwinda
Keyword(s):  
Mild Steel ◽  
Representative Sample ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Orthogonal Metal Cutting

The purpose of this research was to develop models for the prediction of responses from orthogonal metal cutting process that are responsible for the machinability ratings of this technological system. Mild steel work-piece material that is representative sample for various industrial applications was machined. The various industrial applications of this representative sample range from mechanical shafts to fasteners, screws and hydraulic jack. These machine elements require high degree of surface finish. A fifteen-run based Box-Behnken response surface design was created using widely established machining parameters, namely cutting speed, feed rate and depth of cut. The optimum predicted responses from the orthogonal cutting process for the optimal process parameters are 0.1742 micron, 0.4933 micron, 0.1845 micron, 0.3673 micron, 794.6839 seconds and 19.642 seconds for the Ra, Rz, Rq, Rt, TL and M/C time respectively. The associated desirabilities for these optimum responses are 1.000000, 1.000000, 1.000000, 1.000000, 0.524122, and 0.361858 respectively.   http://dx.doi.org/10.4314/njt.v36i1.13

scholarly journals Cutting Forces Prediction in the Dry Slotting of Aluminium Stacks

2014 ◽  
Vol 797 ◽  
pp. 47-52
Author(s):  
Jorge Salguero ◽  
Madalina Calamaz ◽  
Moisés Batista ◽  
Franck Girot ◽  
Mariano Marcos Bárcena
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Parametric Models ◽  
Cutting Process ◽  
Cutting Force Components ◽  
Force Components ◽  
Input Variables ◽  
The Individual

Cutting forces are one of the inherent phenomena and a very significant indicator of the metal cutting process. The work presented in this paper is an investigation of the prediction of these parameters in slotting processes of UNS A92024-T3 (Al-Cu) stacks. So, cutting speed (V) and feed per tooth (fz) based parametric models, for experimental components of cutting force, F(fz,V) have been proposed. These models have been developed from the individual models extracted from the marginal adjustment of the cutting force components to each one of the input variables: F(fz) and F(V).

Simulation and Modeling Method for Micro Turn-Milling Cutting Process

2012 ◽  
Vol 190-191 ◽  
pp. 182-186
Author(s):  
Zeng Wu Zhao ◽  
Xin Jin ◽  
Zhi Jing Zhang ◽  
Xu Yao Sun ◽  
Yong Jun Deng
Keyword(s):  
Cutting Force ◽  
Cutting Speed ◽  
Element Model ◽  
Modeling Method ◽  
Cutting Process ◽  
Machining Accuracy ◽  
Simulation And Modeling ◽  
Accuracy Control ◽  
Experiment Verification ◽  
Turn Milling

A simulation and modeling method for micro turn-milling cutting process was investigated to predict the impacts of cutting speed and cutting depth on cutting force. Based on material Johnson-Cook constitutive model and chip separation criteria, the finite element model was established in ABAQUS simulation application, then the model analysis and experiment verification was conducted. The results indicate that the simulation model can predict the value and regularity of cutting force, which can provide guidance on process optimization and machining accuracy control.

Preliminary Study: The Effect of Tool Engagement and Cutting Speed on Cutting Temperature during Contour Tool Path Strategy

2015 ◽  
Vol 1115 ◽  
pp. 86-89
Author(s):  
Roshaliza Hamidon ◽  
Erry Y.T. Adesta ◽  
Muhammad Riza
Keyword(s):  
Cutting Force ◽  
Tool Path ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Engagement Angle ◽  
Preliminary Study ◽  
Cutting Speeds

In pocketing operation for mold and die, the variation of tool engagement angle causes variation in the cutting force and also cutting temperature. The objective of this study is to investigate the effect of tool engagement on cutting temperature when using the contour in tool path strategy for different cutting speeds. Cutting speeds of 150, 200 and 250m/min, feedrate from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were applied for the cutting process. The result shows that by increasing cutting speed, the cutting temperature would rise. Varying the tool engagement also varied the cutting temperature. This can be seen clearly when the tool makes a 90oturn and along the corner region. Along the corner, the engagement angle varies accordingly with the radial depth of cut.

Three-Dimensional Finite Element Simulation of Cylindrical Turning of Titanium Alloys

2010 ◽  
Vol 44-47 ◽  
pp. 2573-2577 ◽  
Author(s):  
Yu Su
Keyword(s):  
Finite Element ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Parameters ◽  
Element Model ◽  
Depth Of Cut ◽  
Tool Temperature

The understanding of cutting mechanism is important for the improvement of machinability of difficult-to-cut materials. Finite element method (FEM) is an effective way to study the metal cutting process. This paper establishes a finite element model of cylindrical turning of titanium alloys, and then simulates cutting force and tool temperature distribution under different cutting parameters. The simulation results show that in the high-speed cylindrical turning of titanium alloys, depth of cut has a greater influence on principal cutting force than feed rate, while the effect of feed rate on the maximum tool temperature is more distinct than that of depth of cut.

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