Structural Design of Groove and Micro-Blade of the End Mill Based on Bionics

2016 ◽  
Vol 693 ◽  
pp. 1221-1227 ◽  
Author(s):  
Zhen Xi Jiang ◽  
Jie Sun ◽  
Jian Feng Li
Keyword(s):  
Structural Design ◽  
Heat Dissipation ◽  
Orthogonal Cutting ◽  
End Mill ◽  
Squeezing Effect ◽  
Serrated Chip ◽  
Machined Surface ◽  
Cubic Curve ◽  
Mill Machining ◽  
Cutting Model

The existing end mill is hard to balance the tool rigidity, heat dissipation and chip evacuation. In this study, the geometries of groove and micro-blade of the end mill machining titanium are optimized, through imitating the corn leaf’s tooth based on bionics. The peripheral cutting edge is composed of linear first rake, parabolic second rake and rear face. The chip-hold groove is composed of parabolic main groove and cubic curve vice groove. The cutting process of straight tooth and designed composite tooth are simulated by constructing the two-dimensional orthogonal cutting model using ABAQUS. The results show that: compared to the straight tooth, the designed composite tooth inhibits the generation of serrated chip, and the fluctuations of cutting force are smaller, the squeezing effect on the machined surface is weaker.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Finite Element Modeling of Orthogonal Cutting of Pyrolytic Carbon

2011 ◽  
Author(s):  
Gautam Salhotra ◽  
Vivek Bajpai ◽  
Ramesh K. Singh
Keyword(s):  
Finite Element ◽  
Transverse Isotropy ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Pyrolytic Carbon ◽  
Cutting Conditions ◽  
Prediction Errors ◽  
Machining Parameters ◽  
Machined Surface ◽  
Cutting Model

Engineered features on pyrolytic carbon (PyC) have been demonstrated as an approach to improve the flow hemodynamics of the cardiovascular implants. In addition, it also finds application in thermonuclear components. These micro/meso scale engineered features are required to be machined onto the PyC leaflet. However, being a layered anisotropic material and brittle in nature, its machining characteristics differ from plastically deformable isotropic materials. Consequently, this study is aimed at creating a finite element model to understand the mechanics of material removal in the plane of transverse isotropy (horizontally stacked laminae) of PyC. A layered model approach has been used to capture the interlaminar shearing and brittle fracture during machining. A cohesive element layer has been used between the chip layer and the machined surface layer. The chip layer and workpiece are connected through a cohesive layer. The model predicts cutting forces and the chip length for different cutting conditions. The orthogonal cutting model has been validated against experimental data for different cutting conditions for cutting and thrust forces. Parametric studies have also been performed to understand effect of machining parameters on machining responses. This model also predicts chip lengths which have also been compared with the actual chip morphology obtained from microgrooving experiments. The prediction errors for cutting force and chip length are within 20% and 33%, respectively.

The Simulation Analysis of Friction Effect on Cutting Process

2011 ◽  
Vol 314-316 ◽  
pp. 1065-1068
Author(s):  
Shu Jun Li ◽  
Xiao Hang Wan ◽  
Zhao Wei Dong ◽  
Yuan Yuan
Keyword(s):  
Friction Coefficient ◽  
Coulomb Friction ◽  
Simulation Analysis ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Cutting Process ◽  
Machined Surface ◽  
System Description ◽  
Cutting Model

Adopted the Lagrange quality point coordinate system description method used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the ameliorated Coulomb friction theory to simulate the friction status between the chips and tools. This paper simulates the cutting process with different friction coefficient. It can draw conclusions that the cutting forces and the residual stresses of machined surface are increasing with the raising of touching length of rake face and chip, the raising of cutting temperature. The friction coefficient has the important effect on the machining quality.

Development of the cBN Electroplated End-Mill for High Precision Machining of CFRP

2020 ◽  
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Drop Out ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Milled Surface ◽  
Grinding Conditions ◽  
Grinding Tool

Abstract Recently, the demand of carbon fiber reinforced plastics (CFRP) has been rapidly increased in various fields. In most cases, CFRP products requires a finish machining like cutting or grinding. In the case of an end-milling, burrs and uncut fibers are easy to occur. On the other hand, a precise machined surface and edge will be able to obtain by using the grinding tool. Therefore, this research has been developed a novel the cBN electroplated end-mill that combined end-mill and grinding tool. In this report, the effectiveness of developed tool was investigated. First, the developed tool cut the CFRP with side milling. As the result, the cBN abrasives that were fixed on the outer surface of developed tool did not drop out. Next, the end-milled surface of CFRP was ground with the developed tool under several grinding conditions based on the Design of Experiment. Consequently, the optimum grinding condition that can obtain the sharp edge which does not have burrs and uncut fibers was found. However, surface roughness was not good enough. Thus, an oscillating grinding was applied. In addition, the theoretical surface roughness formula in case using the developed tool was formularized. As the result, the required surface roughness in the airplane field was obtained.

scholarly journals Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 397
Author(s):  
Bin Zhou ◽  
Weiwei Zhang ◽  
Zhongmei Gao ◽  
Guoqiang Luo
Keyword(s):  
Grain Size ◽  
Work Hardening ◽  
Inconel 718 ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Machined Surface ◽  
Work Hardening Behavior ◽  
Hardening Behavior ◽  
Significant Difference ◽  
Optimization Of Cutting Parameters

As a representative type of superalloy, Inconel 718 is widely employed in aerospace, marine and nuclear industries. The significant work hardening behavior of Inconel 718 can improve the service performance of components; nevertheless, it cause extreme difficulty in machining. This paper aims to investigate the influence of chamfered edge parameters on work hardening in orthogonal cutting of Inconel 718 based on a novel hybrid method, which integrates Coupled Eulerian-Lagrangian (CEL) method and grain-size-based functions considering the influence of grain size on microhardness. Orthogonal cutting experiments and nanoindentation tests are conducted to validate the effectiveness of the proposed method. The predicted results are highly consistent with the experimental results. The depth of work hardening layer increases with increasing chamfer angle and chamfer width, also with increasing feed rate (the uncut chip thickness). However, the maximum microhardness on the machined surface does not exhibit a significant difference. The proposed method can provide theoretical guidance for the optimization of cutting parameters and improvement of the work hardening.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

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