Experimental Study on Cutting Force and Cutting Power in High Feed Milling of Ti5Al5Mo5VCrFe

2016 ◽  
Vol 836-837 ◽  
pp. 88-93
Author(s):  
Hui Sun ◽  
Hu Xiao ◽  
Liang Li
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rough Machining ◽  
Cutting Power ◽  
Actual Output ◽  
Calculation Results ◽  
High Feed ◽  
Coated Carbide ◽  
Carbide Inserts

In order to improve the rough machining efficiency of titanium alloy, experiments were carried out to investigate the influence of feed per tooth on cutting force and cutting power with index-able coated carbide inserts. The curves of cutting parameters, including cutting force and cutting power, were obtained by single factor test. The results showed that, as the feed per tooth increases, the cutting force increases, especially in the direction of cutting width. All forces almost changed linearly with the changing of feed, and the cutting force of feed direction was the smallest force among the three directions of cutting force. The analytical model of tangential cutting force in the x-y plane was established. By calculating average chip thickness and relationships between tangential cutting force and measurements of cutting force to predict the cutting power, the calculation results were accurate which compared with the actual output power of the machine tool.

Investigation of Surface Roughness and Resulting Cutting Force for Dry Turning Operation of Different Types of Material Using CVD Coating Carbide Tool

2020 ◽  
Vol 50 ◽  
pp. 162-176
Author(s):  
Sophal Hai ◽  
Sung Hoon Oh ◽  
Kyo Seok Park ◽  
Hyung Gon Shin
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Parameters ◽  
Experimental Conditions ◽  
Turning Operation ◽  
Dry Turning ◽  
Main Effect ◽  
Level 1 ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, dry turning operation was carried out on four types of workpiece materials SCM420, SCM420H, SCM440 and SM45C in order to review the effect of cutting parameters on surface roughness (Ra) and resulting cutting force (F). The turning operation was conducted on the NC lathe with the CVD coated carbide inserts. The analysis of variance (ANOVA), linear regression model and main effect plot for mean were employed to investigate the correlation between responses (Ra and F) and cutting parameters. The predictive equations showed a satisfactory correlation with high coefficients of determination (R2) from 80.76 to 98.89%. The lowest feed rate and highest spindle speed were applied to minimize surface roughness, but both were performed at level 1 to minimize the resulting cutting force. The optimal experimental conditions showed the brilliant results as the surface roughness 1 μm and resulting cutting force 39.92 N. The SCM440 steel indicated the best surface roughness responses followed by SCM420, SCM420H and SM45C steel. The SCM440 steel revealed the lowest resulting cutting force followed by SCM420, SM45C and SCM420H steel.

Predictive Modeling of Nonlinear Regenerative Chatter via Measurement, Analysis, and Simulation

1999 ◽  
Author(s):  
J. R. Pratt ◽  
M. A. Davies ◽  
M. D. Kennedy ◽  
T. Kalmár-Nagy
Keyword(s):  
Cutting Force ◽  
Initial Conditions ◽  
Stability Boundary ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Computational Techniques ◽  
Regenerative Chatter ◽  
Stability Lobe ◽  
Measurement Analysis ◽  
On Chip

Abstract A single-degree-of-freedom active cutting fixture is employed to reveal and analyse the hysteretic nature of the lobed stability boundary in a simple machining experiment. Specifically, the seventh stability lobe of a regenerative cutting process is mapped using experimental, analytical, and computational techniques. Then, taking width of cut as a control parameter, the transition from stable cutting to chatter is observed experimentally. The cutting stability is found to possess a substantial hysteresis so that either stable or chattering tool motions can exist at the same nominal cutting parameters, depending on initial conditions. This behavior is predicted by applying nonlinear regenerative chatter theory to an empirical characterization of the cutting force dependence on chip thickness. Time-domain simulations that incorporate both the nonlinear cutting force dependence on chip thickness and the multiple-regenerative effect due to the tool leaving the cut are shown to agree both qualitatively and quantitatively with experiment.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

Investigation of Cutting Force in High Feed Milling of Ti6Al4V

2013 ◽  
Vol 770 ◽  
pp. 106-109 ◽  
Author(s):  
Jie Xu ◽  
Bin Rong ◽  
Hong Zhou Zhang ◽  
Dong Sheng Wang ◽  
Liang Li
Keyword(s):  
Titanium Alloys ◽  
Cutting Force ◽  
Aerospace Industry ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Increasing Trend ◽  
High Feed ◽  
Series Of Experiments ◽  
Titanium Alloy Ti6al4v

Titanium alloys are widely used in aviation and aerospace industry due to their special mechanical properties. In the process of machining titanium alloys, cutting force is an important physical quantity. In this paper, a series of experiments were carried out to investigate the cutting force in detail during high feed milling of titanium alloy Ti6Al4V with different high feed cutters. Effects of cutting parameters, such as milling speed, feed per tooth, radial cutting depth and axial cutting depth on cutting force were analyzed. The results showed that cutting force presented an obvious increasing trend with the increase of feed per tooth and axial cutting depth. However, the effects of cutting speed and radial cutting depth on cutting force were not obvious.

scholarly journals Neural Network Modeling of Cutting Force and Chip Thickness Ratio for Turning Aluminum Alloy 7075-T6

2018 ◽  
Vol 14 (1) ◽  
pp. 67-76
Author(s):  
Mohanned Mohammed H. AL-Khafaji
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Feed Force ◽  
Machining Force ◽  
Force Components

The turning process has various factors, which affecting machinability and should be investigated. These are surface roughness, tool life, power consumption, cutting temperature, machining force components, tool wear, and chip thickness ratio. These factors made the process nonlinear and complicated. This work aims to build neural network models to correlate the cutting parameters, namely cutting speed, depth of cut and feed rate, to the machining force and chip thickness ratio. The turning process was performed on high strength aluminum alloy 7075-T6. Three radial basis neural networks are constructed for cutting force, passive force, and feed force. In addition, a radial basis network is constructed to model the chip thickness ratio. The inputs to all networks are cutting speed, depth of cut, and feed rate. All networks performances (outputs) for all machining force components (cutting force, passive force and feed force) showed perfect match with the experimental data and the calculated correlation coefficients were equal to one. The built network for the chip thickness ratio is giving correlation coefficient equal one too, when its output compared with the experimental results. These networks (models) are used to optimize the cutting parameters that produce the lowest machining force and chip thickness ratio. The models showed that the optimum machining force was (240.46 N) which can be produced when the cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.27 mm/rev). The proposed network for the chip thickness ratio showed that the minimum chip thickness is (1.21), which is at cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.17 mm/rev).

scholarly journals Modeling and Optimization of Cutting Parameters during Machining of Austenitic Stainless Steel AISI304 Using RSM and Desirability Approach

2020 ◽  
Vol 65 (1) ◽  
pp. 10-26
Author(s):  
Septi Boucherit ◽  
Sofiane Berkani ◽  
Mohamed Athmane Yallese ◽  
Riad Khettabi ◽  
Tarek Mabrouki
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Desirability Approach ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

In the current paper, cutting parameters during turning of AISI 304 Austenitic Stainless Steel are studied and optimized using Response Surface Methodology (RSM) and the desirability approach. The cutting tool inserts used in this work were the CVD coated carbide. The cutting speed (vc), the feed rate (f) and the depth of cut (ap) were the main machining parameters considered in this study. The effects of these parameters on the surface roughness (Ra), cutting force (Fc), the specific cutting force (Kc), cutting power (Pc) and the Material Removal Rate (MRR) were analyzed by ANOVA analysis.The results showed that f is the most important parameter that influences Ra with a contribution of 89.69 %, while ap was identified as the most significant parameter (46.46%) influence the Fc followed by f (39.04%). Kc is more influenced by f (38.47%) followed by ap (16.43%) and Vc (7.89%). However, Pc is more influenced by Vc (39.32%) followed by ap (27.50%) and f (23.18%).The Quadratic mathematical models, obtained by the RSM, presenting the evolution of Ra, Fc, Kc and Pc based on (vc, f, and ap) were presented. A comparison between experimental and predicted values presents good agreements with the models found.Optimization of the machining parameters to achieve the maximum MRR and better Ra was carried out by a desirability function. The results showed that the optimal parameters for maximal MRR and best Ra were found as (vc = 350 m/min, f = 0.088 mm/rev, and ap = 0.9 mm).

Cutting Force Changes during One Cut in End Milling with a Throw-Away Insert - Difference between Up-Cut and Down-Cut –

2019 ◽  
Vol 825 ◽  
pp. 123-128
Author(s):  
Kota Matsuda ◽  
Ryutaro Tanaka ◽  
Katsuhiko Sekiya ◽  
Keiji Yamada
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Tangential Force ◽  
Chip Thickness ◽  
Radial Force ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Aisi 1045 ◽  
Tangential Forces ◽  
Coated Carbide

In this study, the transition of cutting force in the tangential and radial direction during one cut was investigated in milling of AISI-1045, AISI-304, and Ti-6Al-4V with a TiN coated carbide throw-away insert. In the case of 1045 and Ti-6Al-4V, there was not obvious difference in tangential forces between up-cut and down-cut. However, up-cut showed larger radial force than down-cut in any material. In down-cut, tangential force showed almost the same regardless of radial depth of cut. 304 and Ti-6Al-4V caused larger radial force with the increase of radial depth of cut at the same cut chip thickness.

Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness of Quartz Glass

2013 ◽  
Vol 641-642 ◽  
pp. 367-370
Author(s):  
Gui Qiang Liang ◽  
Fei Fei Zhao
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Diamond Wheel ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Feed Force

Abstract In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force and cutting force) and surface roughness in milling of Quartz glas using diamond wheel. The cutting process in the up-cut milling of glass is discussed and the cutting force measured. The cutting force gradually increases with the cutter rotation at the beginning of the cut, and oscillates about a constant mean value after a certain undeformed chip thickness. The results show that cutting forces and surface roughness do not vary much with experimental cutting speed in the range of 55–93 m/min. The suggested models of cutting forces and surface roughness and adequately map within the limits of the cutting parameters considered.

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