Effects of Tool Geometrical Parameters on the Chip Formation and Cutting Force in Orthogonal Cutting

2004 ◽  
Vol 471-472 ◽  
pp. 16-20 ◽  
Author(s):  
Gang Fang ◽  
P. Zeng
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Coupling Effect ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Geometrical Parameters ◽  
Actual Process ◽  
Mechanical Coupling ◽  
Chip Separation

The tool plays an important role in cutting process. The aim of this paper is to investigate the effect of tool geometrical parameters on the chip formation and cutting force with orthogonal cutting models. The large deformation Rigid-visco-plastic FEM program DEFORM-2DTM is used, and thermo-mechanical coupling effect are considered. The chip separation from workpiece is implemented by remeshing. Contrary to traditional cutting simulation, the workpiece is moved and the tool is fixed, which is consistent with actual process. The effects of tool rake angle on the chip geometry and cutting force are analyzed. The simulated cutting forces are compared with results in other references. The research results are a help to cutting process study and cutting tool design.

A FEM and Experimental Study of Chip Formation in Orthogonal Cutting of Superalloy GH80A

2009 ◽  
Vol 626-627 ◽  
pp. 663-668
Author(s):  
Jun Li Li ◽  
Ming Chen ◽  
Bin Rong
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Rake Angle ◽  
Cutting Process ◽  
High Yield ◽  
Isotropic Model ◽  
On Chip ◽  
As Stress

The nickel-based superalloy GH80A has been widely used in kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at high temperature. However, it is also a typical difficult-to-cut material. In order to improve cutting process, kinds of methods have been applied to study cutting process including experimental approach and finite element method (FEM). In this paper, a comparison of chip formation is carried out between traditional Johnson-Cook (JC) model and Isotropic model. Besides, effects of tool rake angle and friction coefficient on chip formation are investigated by Isotropic model. FEM predicated results such as stress and cutting temperature are also analyzed. Relative turning tests are performed and comparison of chip morphology between FEM and experiment is carried out.

Numerical Simulation of Orthogonal Cutting Process of a Kind of Difficult-to-Cut Material

2006 ◽  
Vol 532-533 ◽  
pp. 925-928 ◽  
Author(s):  
Jing Sheng ◽  
Wei Zheng Yuan
Keyword(s):  
Orthogonal Cutting ◽  
Simulated Data ◽  
Element Model ◽  
Parametric Modeling ◽  
Constitutive Law ◽  
Cutting Process ◽  
Initial State ◽  
Workpiece Material ◽  
Mechanical Coupling ◽  
Chip Separation

A orthogonal cutting of a kind of difficult-to-cut material is simulated using a finite element model, which is considered dynamic effects, thermo-mechanical coupling, tool-chip friction, chip separation criteria. Marc program is the computational tool in the model. Johnson-Cook’s model is employed as the constitutive law for the workpiece material. The frictional behavior of the sticking and sliding tool-chip interface is described by Coulomb’s law. Remeshing technique and mesh adaptive technique are also used. The research mainly specializes plane strain and continuous flow chip. The emphasis is placed on the parametric modeling of tool and workpiece. Then the cutting force and temperature in cutting process from initial state to steady state is conducted by simulation. Finally the Experimental value is compared with the simulated data.

Machining FEM Model of Unidirectional Carbon Fiber Reinforced Laminate

2012 ◽  
Vol 601 ◽  
pp. 105-109
Author(s):  
Jing Yi Wang ◽  
Yan Li He ◽  
Xu Wang
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Surface Damage ◽  
Cutting Process ◽  
Fe Model ◽  
Cfrp Laminate ◽  
Finite Element Software ◽  
Chip Formation Mechanism

A two-dimensional macro-mechanical finite element (FE) model is developed to study the orthogonal cutting process of CFRP unidirectional laminate by the finite element software ABAQUS. The CFRP laminate is defined as an equivalent orthotropic, homogeneous single-phase material. On the basis of composite unidirectional laminate plane stress-strain and strength theory, the author adopts Hashin progressive damage criteria in the FE model. Based on the results of finite element simulation, the changes of cutting force in the chip formation process of CFRP laminate are analyzed, the Hashin damage in the cutting process and the influences of fiber orientation on cutting force, chip formation mechanism and sub-surface damage are explored as well. The comparison between this paper and previous related research shows that the results have a reasonable agreement with the previous achievements.

Rigid-Plastic FEM Simulation of Orthogonal Cutting Process

2011 ◽  
Vol 338 ◽  
pp. 209-213
Author(s):  
Jiang Xin Zhu ◽  
Jian Xin Deng
Keyword(s):  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Rake Angle ◽  
Cutting Process ◽  
Analysis Model ◽  
Rigid Plastic ◽  
Fem Model ◽  
On Chip ◽  
Chip Separation

This paper presents a rigid-plastic finite element method for orthogonal cutting process by adopting Lagrange method. The rigid-plastic FEM analysis model is established and the rigid-plastic FEM analysis toolkit was developed. Meanwhile, two relevant key problems are discussed systematically, including the rule of chip-workpiece separation and the criterion of tool-chip separation. At last, a simulation example of planing an aluminium alloy (ZL-301) workpiece was conducted. The effects of the cutting stroke, the tool rake angle and the friction coefficient on chip were observed. The numerical simulation results have a good agreement with their experimental ones. It is indicated that the presented FEM model and algorithm are efficient and correct.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

Using Image Analysis Techniques for Single Evaluation of the Chip Shrinkage Factor in Orthogonal Cutting Process

2012 ◽  
Vol 504-506 ◽  
pp. 1329-1334 ◽  
Author(s):  
Moises Batista ◽  
Madalina Calamaz ◽  
Franck Girot ◽  
Jorge Salguero ◽  
Mariano Marcos
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Shrinkage Factor ◽  
A Value ◽  
Chip Shrinkage ◽  
Chip Geometry ◽  
Image Analysis Techniques

The forces involved in a cutting process are related, for example, with the power consumption, with the final quality of the workpiece and with the chip geometry obtained, since these forces determine the compression experimented by the chip and therefore its final geometry. The orthogonal cutting process assisted with a High Speed Filmation (HSF) permit obtains a digital filmation of the process with high magnification. This filmation permits to obtain a measurement of the longitudinal changes produced in the chip. This deforms are related with the Shrinkage Factor, ζ. And in this case the Stabler hypothesis is enabled, by that using the shear angle and the rake angle is possible obtain a value of the Shrinkage Factor in a different conditions.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

Simulation of Chip Formation in an Orthogonal Cutting Process Using Fem

2002 ◽  
pp. 167-177 ◽  
Author(s):  
G. Giorleo ◽  
R. Teti ◽  
A. Langella ◽  
D. D’Addona ◽  
U. Prisco
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Process

Cyclic shear angle for lamellar chip formation in ultra-precision machining

2020 ◽  
Vol 234 (13) ◽  
pp. 2673-2680 ◽  
Author(s):  
Shaojian Zhang ◽  
Pan Guo ◽  
Zhiwen Xiong ◽  
Suet To
Keyword(s):  
Chip Formation ◽  
Diamond Tool ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Shear Angle ◽  
Precision Machining ◽  
Cyclic Shear ◽  
Intrinsic Mechanism ◽  
Classical Models ◽  
Ultra Precision

Shear angle is classically considered constant. In the study, a series of straight orthogonal cutting tests of ultra-precision machining revealed that shear angle cyclically evolved with each lamellar chip formation, i.e. cyclic shear angle. It grew up from an initial shear angle of 0° to a final shear angle 90°- α ( α: tool rake angle) and underwent a series of transient shear angles like classical shear angles and a critical shear angle. The critical shear angle is the sum of the half of the tool rake angle and the characteristic shear angle determined by material anisotropy without the friction effect. Moreover, a new model was developed. Further, a series of face turning tests of ultra-precision machining verified that the cyclic shear angle was the intrinsic mechanism of cyclic cutting forces and lamellar chip formation to induce twin-peak high-frequency multimode diamond-tool-tip vibration. Significantly, the study draws up an understanding of shear angle for the discrepancy among the classical models.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

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