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.

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.

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.

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.

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%.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

Experimental study and multi-objective optimization of process parameters during turning of 100Cr6 using C-type advanced coated tools

2021 ◽  
pp. 095440622110431
Author(s):  
LR Bhandarkar ◽  
PP Mohanty ◽  
SK Sarangi
Keyword(s):  
Cutting Force ◽  
Distance Measure ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
X Ray ◽  
Coated Tools ◽  
Reduction Coefficient ◽  
Machining Parameter

The drive of this research is to examine the machinability of 100Cr6 bearing steel using advanced C-type cutting tools. Experimental studies investigated the effects of machining variables on the surface quality, chip reduction coefficient and cutting force. Seven advanced coated tools were checked for characterization by micro hardness (VHN), adhesion quality, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDXS). The experimental trials were planned by Taguchi’s L18 orthogonal array using a mixed-level design. Two numerical machining variables feed rate and cutting speed, and one categorical machining variable tool type was taken into consideration while a constant depth of cut was kept for all trails. A combined Taguchi-Satisfaction function distance measure approach was implemented for multi-response optimization. The most promising machining parameter setting for minimization of surface roughness, cutting force, and chip reduction coefficient was identified. The most important process parameter was found to be tool-type. Ceramics tools are found to be best trailed by WC coated tools under most of the conditions. Lower tool wear was observed in the CBN tool as compared to others.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

Application of MCDM-based TOPSIS method for the selection of optimal process parameter in turning of pure titanium

2017 ◽  
Vol 24 (7) ◽  
pp. 2009-2021 ◽  
Author(s):  
Akhtar Khan ◽  
Kalipada Maity
Keyword(s):  
Decision Making ◽  
Cutting Force ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Optimal Combination ◽  
Depth Of Cut ◽  
Topsis Method ◽  
Content Type ◽  
Cp Ti ◽  
Selection Of

Purpose The purpose of this paper is to explore a multi-criteria decision-making (MCDM) methodology to determine an optimal combination of process parameters that is capable of generating favorable dimensional accuracy and product quality during turning of commercially pure titanium (CP-Ti) grade 2. Design/methodology/approach The present paper recommends an optimal combination of cutting parameters with an aim to minimize the cutting force (Fc), surface roughness (Ra), machining temperature (Tm) and to maximize the material removal rate (MRR) after turning of CP-Ti grade 2. This was achieved by the simultaneous optimization of the aforesaid output characteristics (i.e. Fc, Ra, Tm, and MRR) using the MCDM-based TOPSIS method. Taguchi’s L9 orthogonal array was used for conducting the experiments. The output responses (cutting force: Fc, surface roughness: Ra, machining temperature: Tm and MRR) were integrated together and presented in terms of a single signal-to-noise ratio using the Taguchi method. Findings The results of the proposed methodology depict that the higher MRR with desirable surface quality and the lower cutting force and machining temperature were observed at a combination of cutting variables as follows: cutting speed of 105 m/min, feed rate of 0.12 mm/rev and depth of cut of 0.5 mm. The analysis of variance test was conducted to evaluate the significance level of process parameters. It is evident from the aforesaid test that the depth of cut was the most significant process parameter followed by cutting speed. Originality/value The selection of an optimal parametric combination during the machining operation is becoming more challenging as the decision maker has to consider a set of distinct quality characteristics simultaneously. This situation necessitates an efficient decision-making technique to be used during the machining operation. From the past literature, it is noticed that only a few works were reported on the multi-objective optimization of turning parameters using the TOPSIS method so far. Thus, the proposed methodology can help the decision maker and researchers to optimize the multi-objective turning problems effectively in combination with a desirable accuracy.

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

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