scholarly journals Analytical model of temperature distribution in metal cutting based on Potential Theory

2015 ◽  
Vol 6 (2) ◽  
pp. 89-94 ◽  
Author(s):  
F. Klocke ◽  
M. Brockmann ◽  
S. Gierlings ◽  
D. Veselovac
Keyword(s):  
Potential Theory ◽  
Analytical Model ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Temperature Fields ◽  
Wear Behaviour ◽  
Work Piece ◽  
Machining Processes ◽  
Major Interest ◽  
Cutting Processes

Abstract. Temperature fields evolving during metal cutting processes have also been of major interest. Temperatures in the tool influence the wear behaviour and hence costs, temperatures in the work-piece are directly responsible for later product quality. Due to the high significance of temperatures, many modelling attempts for temperature fields have been conducted, however failed to deliver satisfying results. The present paper describes a novel analytical model using complex functions based on potential theory. Relevant heat sources in metal cutting as well as changing material constants are considered. The model was validated by an orthogonal cutting process and different real machining processes.

Analytical Modelling of Temperature Distribution Using Potential Theory by Reference to Broaching of Nickel-Based Alloys

2013 ◽  
Vol 769 ◽  
pp. 139-146 ◽  
Author(s):  
Sascha Gierlings ◽  
Matthias Brockmann
Keyword(s):  
Metal Cutting ◽  
Temperature Fields ◽  
Aviation Industry ◽  
Work Piece ◽  
Machined Surface ◽  
Tool Wear Mechanisms ◽  
Critical Components ◽  
Aero Engines ◽  
Tool Centre Point ◽  
Cutting Processes

Knowledge of temperature fields and heat flow evolving during metal cutting processes is of significant importance for ensuring and predicting the product`s quality. Furthermore, this knowledge enables an improved usage of resources, such as machine tools and tool deployment. The strength of the heat sources as a result of the process and the distribution of the temperature in the material directly influence the tool wear mechanisms, wear rate, thermo-elastic deflection of the tool centre point and the amount of heat flowing into the newly generated work piece surface. Especially the latter effect is of crucial importance when it comes to safety critical components as they are employed in aero-engines. In aviation industry, the surface integrity is used as a complex quality measure summarising several aspects at the machined surface and sub-surface out of which many issues are predominantly thermal issues (e.g. temperature driven hardening of the work piece material, re-cast and white etching layers as well as residual stress profiles).

scholarly journals Partition of Primary Shear Plane Heat in Orthogonal Metal Cutting

2020 ◽  
Vol 4 (3) ◽  
pp. 82
Author(s):  
Lars Langenhorst ◽  
Jens Sölter ◽  
Sven Kuschel
Keyword(s):  
Metal Cutting ◽  
Numerical Models ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Shear Plane ◽  
Machining Processes ◽  
Heat Partition ◽  
Realistic Representation ◽  
Cutting Velocity ◽  
Cutting Processes

When assessing the effect of metal cutting processes on the resulting surface layer, the heat generated in the chip formation zone that is transferred into the workpiece is of major concern. Models have been developed to estimate temperature distributions in machining processes. However, most of them need information on the heat partition as input for the calculations. Based on analytical and numerical models, it is possible to determine the fraction of shear plane heat transferred into the workpiece for orthogonal cutting conditions. In the present work, these models were utilized to gain information on the significant influencing factors on heat partition, based on orthogonal cutting experiments, experimental results from the literature, and a purely model-based approach. It could be shown that the heat partition does not solely depend on the cutting velocity, the uncut chip thickness, and the thermal diffusivity—combined in the dimensionless thermal number—but the shear angle also has to be taken into account, as already proposed by some researchers. Furthermore, developed numerical models show that a more realistic representation of the process kinematics, e.g., regarding chip flow and temperature-dependent material properties, do not have a relevant impact on the heat partition. Nevertheless, the models still assume an idealized orthogonal cutting process and comparison to experimental-based findings on heat partition indicates a significant influence of the cutting edge radius and the friction on the flank face of the tool.

scholarly journals Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

2021 ◽  
Author(s):  
Hui Liu ◽  
Markus Meurer ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Metal Cutting ◽  
Negative Impact ◽  
Orthogonal Cutting ◽  
Fluid Simulation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Thermomechanical Effect ◽  
Dimensional Simulation ◽  
On Chip ◽  
Cutting Processes

Abstract Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.

Analytical Model of Chip Formation in Case of Orthogonal Cutting Processes

2011 ◽  
Vol 223 ◽  
pp. 101-110
Author(s):  
Ferdinando Salvatore ◽  
Tarek Mabrouki ◽  
Hédi Hamdi
Keyword(s):  
Analytical Model ◽  
Chip Formation ◽  
Material Removal ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Analytical Methodology ◽  
Decomposition Approach ◽  
Industrial Community ◽  
Applied Forces ◽  
Cutting Processes

The present work deals with the presentation of analytical methodology allowing the modeling of chip formation. For that a “decomposition approach”, based on assuming that the material removal is the summation of two contributions, ploughing and pure cut was adopted. Moreover, this analytical model was calibrated by a finite element model and experimental data in terms of temperature and applied forces evolutions. The global aim is to propose to the industrial community, an efficient rapid-execution analytical model concerning the material removal in the case of an orthogonal cutting process.

Identification of Material Constitutive Parameters Using Orthogonal Cutting Tests and Genetic Algorithm

2011 ◽  
Vol 697-698 ◽  
pp. 112-116 ◽  
Author(s):  
B. Lan ◽  
Ping Fa Feng ◽  
Zhi Jun Wu
Keyword(s):  
Genetic Algorithm ◽  
Analytical Model ◽  
Metal Cutting ◽  
Mechanical Characteristics ◽  
Orthogonal Cutting ◽  
Shear Stresses ◽  
Strain Rates ◽  
The Finite Element Method ◽  
Workpiece Material ◽  
Constitutive Parameters

Identification of workpiece material constitutive parameters for their application in the simulation of metal cutting process has been a hot research spot for long. This paper proposes a methodology to address this problem using orthogonal cutting tests and Genetic Algorithm (GA). First, an analytical model which calculates the dynamic characteristics occurring in the primary shear zone is introduced; then, orthogonal cutting tests are carried out, to record the following mechanical characteristics with the analytical model: shear stresses, shear strains, strain rates, cutting temperatures; afterwards, GA is employed to obtain the constitutive parameters from these characteristics; at last, the finite element method (FEM) simulations of the cutting tests are performed to evaluate the predictive accuracies of the obtained parameters. In this paper, a Japanese brand steel SCM440H is used as the workpiece material, and the simulation results of its constitutive parameters show good agreements with the experimental data, which renders the feasibility of the proposed methodology.

scholarly journals Pengaruh Parameter Pemesinan terhadap Kualitas Hasil Potong Mesin Bubut Maximat V13 pada Benda Kerja Poros PVC

2019 ◽  
Vol 2 (02) ◽  
pp. 19-24
Author(s):  
Kasijanto Kasijanto ◽  
Sadar Wahjudi ◽  
Listiyono Listiyono ◽  
Muhammad Fakhruddin
Keyword(s):  
Metal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece ◽  
Machining Processes ◽  
Cutting Surface ◽  
Spindle Rotation ◽  
Feeding Speed ◽  
Tool Types

Metal cutting process (cutting process) is to cut metal to get the shape and size and quality of the planned cutting surface. The metal cutting process is carried out with special tools, according to the type of cutting process. So the tools for one process cannot be used in another process, even for similar processes, the tools cannot be exchanged if the cutting plans are not the same. Lathe process is a machining process to produce cylindrical machine parts which are carried out using a Lathe. Its basic form can be defined as the machining process of the outer surface of cylindrical or flat lathe objects. Polyvinyl Chloride, commonly abbreviated as PVC, is the third-order thermoplastic polymer in terms of total usage in the world, after Polyethylene (PE) and Polypropylene (PP). Worldwide, more than 50% of PVC produced is used in construction. PVC is produced by polymerizing vinyl chloride monomers (CH2 = CHCl). Because 57% of its mass is chlorine, PVC is the polymer that uses the lowest petroleum feedstock among other polymers. This research follows up the selection of configuration of the lathe machining process using plastic work pieces. In this study, Maximat V13 lathe and PVC type plastic were used. The variation of machining processes are spindle rotation (320, 540, and 900 rpm), feeding speed (0.07, 0.14, and 0.28), the use of tool types (carbide and HSS) and cooling (without cooling, coolant, and oil). So, with this research, it is expected that the optimal parameters in determining the configuration of the lathe machining process on a PVC work piece to produce a good turning surface can be achieved  

An Experimental and Computational Study of Temperature and Strain Fields in Metal Cutting

2001 ◽  
Author(s):  
Alan T. Zehnder ◽  
Yogesh K. Potdar ◽  
Xiaomin Deng ◽  
Chandrakant Shet
Keyword(s):  
Spatial Resolution ◽  
Metal Cutting ◽  
Computational Study ◽  
Orthogonal Cutting ◽  
Critical Role ◽  
Rake Angle ◽  
General Purpose ◽  
Temperature Fields ◽  
Ir Detectors ◽  
Strain Fields

Abstract Metal cutting is a thermo-mechanically coupled process in which plasticity induced heating and friction play a critical role. In this paper, we outline a methodology that combines high resolution experiments with numerical simulations. The simulations were performed with a general purpose finite element code. With this code we evaluate the effects of chip-tool interface friction and rake angle on temperature and cutting force and show that results for residual stresses in the workpiece are consistent with experimental data. We hypothesize that by closely coupling simulations to fine scale spatial and temporal experimental measurements of temperature and strain fields, questions related to choice of parameters in FE simulations can be resolved. We have designed and conducted orthogonal cutting experiments to measure temperatures, using IR detectors, with a spatial resolution of 27 × 27 μm and time scale of 200 ns. Experimentally obtained temperature fields are compared with FE results. We also obtain deformation fields with a spatial resolution of 50 × 50 μm.

Basic Mechanics of the Metal-Cutting Process

1944 ◽  
Vol 11 (3) ◽  
pp. A168-A175 ◽  
Author(s):  
M. Eugene Merchant
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Work Piece ◽  
Machining Operations ◽  
Work Done ◽  
Metal Work

Abstract The author presents a mathematical analysis of the geometry and mechanics of the metal-cutting process, covering two common types of geometry which occur in cutting. This analysis offers a key for the study of engineering problems in the field of metal cutting in terms of such fundamental quantities as strain, rate of shear, friction between chip and tool, shear strength of the metal, work done in shearing the metal and in overcoming friction, etc. The two cases covered are, in essence, that of a straight-edged cutting tool moving relative to the work-piece in a direction perpendicular to its cutting edge, termed “orthogonal cutting,” and that of a similar cutting tool so set that the cutting edge is oblique to the direction of relative motion of tool and work, termed “oblique cutting.” Equations are developed which permit the calculation of such quantities as those just enumerated from readily observable values. The theoretical findings are particularly applicable and significant in the case of present-day high-speed machining operations with sintered-carbide tools.

3D Finite Element Simulation on the Orthogonal Cutting Processes with Different Commercial Codes

2011 ◽  
Vol 188 ◽  
pp. 555-560
Author(s):  
Zhao Yu Mou ◽  
Peng Fei Gao ◽  
Wei Fang Wang ◽  
Dong Hui Wen
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Experiment ◽  
Orthogonal Cutting ◽  
Friction Model ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Type Boundary ◽  
Cutting Processes ◽  
Type Boundary Condition

The purpose of this paper is to compare different simulation model of orthogonal cutting process using three different FEM commercial codes as well as with the results of orthogonal experiment. For one thing, element type, boundary condition and friction model between the chip and tool commercial have been compared when the numerical model established in implicit finite element code, Deform3D and the explicit code ANSYS/LS-DYNA and Thirdwave AdvantEdge. For another, main and thrust cutting forces, shear angles, chip thicknesses and contact lengths by three codes are compared with the orthogonal metal cutting experiment by Movahhedy and Altintas.

Investigation of the Impact of Orthogonal Cutting Processes on Nanocrystalline Surface Layer Generation

2013 ◽  
Vol 554-557 ◽  
pp. 2009-2020 ◽  
Author(s):  
Volker Schulze ◽  
Frederik Zanger ◽  
Florian Ambrosy
Keyword(s):  
Grain Size ◽  
Surface Layer ◽  
Cutting Force ◽  
Manufacturing Process ◽  
Orthogonal Cutting ◽  
Work Piece ◽  
Passive Force ◽  
Surface Layers ◽  
Cutting Processes ◽  
The Impact

The present work analyzes the influence of an orthogonal machining process on the generation of nanocrystalline surface layers. Thereby, AISI 4140 is used as work piece material. Metallic parts with a severe nanocrystalline grain refinement in the near-surface area show many beneficial properties. Such surface layers considerably influence the friction and wear characteristics of the work piece in a subsequent usage as design elements working under tribological loads. The focus of this paper is an experimental analysis of a finishing orthogonal cutting operation, carried out with a broaching machine, to generate nanocrystalline surface layers. The influence of process and geometry parameters on the generation of nanocrystalline surfaces is investigated with the aim to massively decrease the grain size in the work piece surface layer. Parameters that are studied and taken into account in the manufacturing process are cutting edge radius rβ, depth of cut h and cutting velocity vc. The cutting edge radius rβ is modified by a drag finishing process. The generation of nanocrystalline surface layers is especially influenced by the design of the uncoated carbide cutting tools. Additionally, cutting force Fc and passive force Fp are determined by a 3-component dynamometer to calculate the relationship between specific cutting force kc and specific passive force kp. The temperature beneath the clearance face is detected by a fiber optic pyrometer. These measurement methods and devices are applied to detect the impact of the most relevant measurement values occurring during machining and causing a drastic reduction of grain size in the surface layer. The evaluation of the manufacturing process is carried out by detailed analyses of the microstructural conditions in the surface layer after processing using a Focused Ion Beam (FIB) system. These material characterizations provide information about the surface engineering concerning the microstructural changes in the surface layer of the work piece due to finishing orthogonal cutting processes.

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