Calculating of the Temperature Distribution of Primary Shear Zone in Orthogonal High Speed Cutting Based on the Non-Uniform Volume Moving Heat Source

2009 ◽  
Vol 626-627 ◽  
pp. 105-110 ◽  
Author(s):  
Guo He Li ◽  
Min Jie Wang
Keyword(s):  
Temperature Distribution ◽  
Heat Source ◽  
Shear Zone ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Constitutive Relationship ◽  
Moving Heat Source ◽  
High Speed Cutting ◽  
Strain And Strain Rate

A method was presented for calculating the temperature distribution of primary shear zone in orthogonal high speed cutting based on the non-uniform volume moving heat source. The temperature distribution of primary shear zone in orthogonal high speed cutting was calculated by the dynamic plastic constitutive relationship and the distribution of strain and strain rate of primary shear zone. The results show that the temperature distribution of primary shear zone is uneven, from the original plane to the cutoff plane, the cutting temperature increases continuously. In the middle of primary shear zone, the change of cutting temperature is larger, at the position near to original plant and cutoff plane, the change of cutting temperature is smaller. The cutting temperature increases with the increase of cutting speed and cutting depth, but decreases with the increase of rake angle. The comparison with existing method shows that the method presented in this paper is not only available, but also simple, convenient and more accord with the fact of orthogonal high speed cutting.

Experimental Research on Cutting Temperature of AISI 1045 in High Speed Milling Process

2014 ◽  
Vol 893 ◽  
pp. 621-624
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental System ◽  
Milling Process ◽  
Thermal Imager ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Aisi 1045

The aim of this paper is to investigate the time dependence distribution of workpiece cutting temperature in milling process. An experimental system used to achieve a measurement of cutting temperature in high speed milling is designed by use of the thermocouple and infrared thermal imager. The general regularity of temperature distribution is concluded, and the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated in detail. All the experiment results can be effective used to develop a new non-contact soft-sensing method for high speed cutting temperature prediction.

Experiment of Temperature Field for High Speed Orthogonal Turning

2011 ◽  
Vol 117-119 ◽  
pp. 594-597 ◽  
Author(s):  
Mu Lan Wang ◽  
Yong Feng ◽  
Xiao Xia Li ◽  
Bao Sheng Wang
Keyword(s):  
Temperature Field ◽  
High Speed ◽  
Model Simulation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental System ◽  
Maximum Temperature ◽  
Fem Model ◽  
High Speed Cutting ◽  
Orthogonal Turning

An experimental system used for temperature measurement is designed by the K-type thermocouple thermometry to achieve a direct measurement of cutting temperature in high speed orthogonal turning. The general regularity of temperature distribution is concluded, and the corresponding influences of cutting speed and cutting depth on the maximum temperature value are discussed in detail. Experimental data and simulating results are comparative analyzed to demonstrate the feasibility and correctness of Finite Element Method (FEM) model simulation and analytical solution. The verified model of temperature field can be applied to develop an effective non-contact soft-sensing method for high speed cutting temperature.

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.

Ultra High-Speed Cutting Experiment under the Cutting Condition that Cutting Speed Exceeds Plastic Wave Speed of Workpiece

2011 ◽  
Vol 325 ◽  
pp. 327-332 ◽  
Author(s):  
Jun Shinozuka ◽  
Masato Sando ◽  
Tasuku Horie
Keyword(s):  
Shock Wave ◽  
Shear Zone ◽  
High Speed ◽  
Cutting Speed ◽  
Experimental Result ◽  
Cutting Condition ◽  
Plastic Wave ◽  
High Speed Cutting ◽  
Ultra High Speed ◽  
Impact Cutting

Raising a cutting speed to above speed of a plastic wave of a workpiece material induces the high levels of the hydrostatic stresses in the shear zone, because a plastic wave traveling there becomes a shock wave. In order to ascertain the cutting phenomena occurring under the ultra high-speed cutting condition, the cutting experiments of a pure lead with cutting speeds of up to 140 m/s are performed with a high-speed impact cutting tester developed. The experimental result reveals that the cutting mechanism, especially chip formation, changes remarkably and the friction angle at the tool-chip interface rises in the ultra high-speed cutting. It can be explained that these phenomena arise from the plastic shock wave in the shear zone.

A Way to Reduce Machine Cutting Temperature

2014 ◽  
Vol 1061-1062 ◽  
pp. 427-430
Author(s):  
Zi Qin Ma ◽  
Yan An Chen ◽  
Peng Fei Zhao ◽  
Tong Wang ◽  
Chen Peng ◽  
...  
Keyword(s):  
High Speed ◽  
Cooling System ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Coolant Temperature ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Machining Center ◽  
Cutting Heat ◽  
Development Direction

High-speed cutting technology has become an important development direction of modern NC machining technology, but the existing equipments are often not suitable for high speed machining. An effective method is proposed in view of the cutting heat in cutting process, by introducing chiller to the existing cooling system, the coolant temperature decrease, tool and workpiece temperature can also reduce, so general machining center can achieve cutting speed as quickly as possible.

Modelling of the cutting temperature distribution under the tool flank wear effect

2003 ◽  
Vol 217 (11) ◽  
pp. 1195-1208 ◽  
Author(s):  
Y Huang ◽  
S Y Liang
Keyword(s):  
Temperature Distribution ◽  
Tool Wear ◽  
Heat Source ◽  
Shear Zone ◽  
Temperature Rise ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Infinite Medium ◽  
Heat Sources ◽  
Moving Band

The understanding of cutting temperature distribution at the presence of tool wear can aid in addressing important metal cutting issues such as part surface integrity, tool life and dimensional tolerance under practical operating conditions. The effect of tool wear on the cutting temperature distribution was first modelled by Chao and Trigger and there have been very few followers since. In Chao's model, the primary heat source was assumed to have no effect on the workpiece temperature rise and the chip temperature rise was treated as a bulk quantity. This paper analytically quantifies the tool wear effect by taking into account the contributions of the primary heat source and considering the distribution of chip temperature rise. On the chip side, the primary shear zone is modelled as a uniform moving oblique band heat source and the secondary shear zone as a non-uniform moving band heat source within a semi-infinite medium. On the tool side, the effects of both the secondary and the rubbing heat sources are modelled as non-uniform static rectangular heat sources within a semi-infinite medium. For the workpiece side, the study models the primary shear zone as a uniform moving oblique band heat source and the rubbing heat source as a non-uniform moving band heat source within a semi-infinite medium. The proposed model is verified based on the published experimental data in the orthogonal cutting of Armco iron. Furthermore, a comparison case is presented on the temperature variation with respect to cutting speed, feed rate and flank wear length.

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%.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

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