Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis

The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

As a representative type of superalloy, Inconel 718 is widely employed in aerospace, marine and nuclear industries. The significant work hardening behavior of Inconel 718 can improve the service performance of components; nevertheless, it cause extreme difficulty in machining. This paper aims to investigate the influence of chamfered edge parameters on work hardening in orthogonal cutting of Inconel 718 based on a novel hybrid method, which integrates Coupled Eulerian-Lagrangian (CEL) method and grain-size-based functions considering the influence of grain size on microhardness. Orthogonal cutting experiments and nanoindentation tests are conducted to validate the effectiveness of the proposed method. The predicted results are highly consistent with the experimental results. The depth of work hardening layer increases with increasing chamfer angle and chamfer width, also with increasing feed rate (the uncut chip thickness). However, the maximum microhardness on the machined surface does not exhibit a significant difference. The proposed method can provide theoretical guidance for the optimization of cutting parameters and improvement of the work hardening.

Fracture energy for orthogonal cutting in unidirectional CFRP at different cutting directions

A unidirectional carbon fibre reinforced polymer (CFRP) laminate is a composite material made up of strong parallel carbon fibres incorporated in a polymer matrix such as epoxy to provide high stiffness and strength in the fibre direction of the laminate. Unfortunately, the interlaminar or intralaminar plane of this material has a low resistance to damages as the fracture toughness of a unidirectional CFRP laminate is related to the energy dissipation during the orthogonal cutting. The aim of this study is on cutting a unidirectional CFRP along the longitudinal or transverse directions, characterizing orthogonal cutting forces and the related fracture energy. Orthogonal cutting is performed using braised carbide tools for a range of cutting depth of 10-100 ³m with a rake angle of 30° to quantify the cutting forces and to observe the fracture mechanisms. The fibre orientations have a significant impact on surface bouncing-back. For some fibre orientations, the energy balance model is applicable, deducting the reasonable value of fracture toughness due to high normal force (F t). Fibre subsurface damage and cutting forces during cutting are found to be strongly influenced by the cutting depth. The input energy of cutting is released in form of new surface energy, fibre breakage, high bending energy, and chip fracture energy.

Shoulder Damage Model and Its Application for Single Point Diamond Machining of ZnSe Crystal

The damaging of ZnSe crystal has a significant impact on its service performance and life. Based on the specific cutting energies for brittle and ductile mode machining, a model is proposed to evaluate the damage depth in the shoulder region of ZnSe crystal during single point diamond machining. The model considers the brittle-ductile transition and spring back of ZnSe crystal. To verify the model, the elastic modulus, hardness, spring back, and friction coefficient of ZnSe crystal are measured by nanoindentation and nanoscratch tests, and its critical undeformed chip thickness is obtained by spiral scratching. Meanwhile, orthogonal cutting experiments are conducted to obtain the different shoulder regions and cutting surfaces. The shoulder damage depth is analyzed, indicating that the effect of the feed on the damage depth at a high cutting depth is stronger than that at a low one. The model is verified to be effective with an average relative error of less than 7%. Then, the model is used to calculate the critical processing parameters and achieve a smooth ZnSe surface with a roughness Sa = 1.0 nm. The model is also extended to efficiently predict the bound of the subsurface damage depth of a cutting surface. The research would be useful for the evaluation of surface and subsurface damages during the ultra-precision machining of ZnSe crystal.