Papers by Keyword: Cutting Force

Abstract: In recent times, the market for the applications of titanium alloys, particularly β alloys, is growing rapidly, calling for higher productivity. However, it is difficult to machine titanium alloys. A number of research activities have been carried out in this area to improve the productivity of titanium machining. Laser assisted machining is one technique which has been proposed to enhance the machinability of various difficult-to-cut materials including titanium alloys. In this study, two β titanium alloys, viz. Ti-10V-2Fe-3Al and Ti-6Cr-5Mo-5V-4Al, were machined using laser assistance and the results were compared with unassisted machining conditions. Their response to laser assisted machining in terms of differences in the cutting forces, cutting temperature and chip formation are reported. It was found that the Ti-6Cr-5Mo-5V-4Al workpiece was much more difficult to machine even with laser assistance.

Abstract: The high speed milling test of CVD composite coated tool cutting natural marble is carried out. Measured milling forces of different parameters by the dynamometer and analyzed the influence of different parameters on the cutting force. Observed the wear appearance by the SEM and analyzed the wear mechanism of CVD tool. The results of the experiment show that the cutting force increases along with the cutting depth and feed speed increase, decreases along with the spindle speed and the influence of the cutting depth is the largest. The wear mechanisms of CVD tool when milling the natural marble include the removal of mechanical loss on the tool substrate, oxidation wear and adhesion wear. The removal of mechanical loss and adhesion wear couple with the whole process of CVD composite coated tool.

Abstract: The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc.... In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions

Abstract: Metal cutting processing is the most fundamental, most widely and the most important processing in industrial production. Because the development of mechanical manufacturing level plays a very important role in the coating technology material machining process. A coated carbide cutting tool with its high hardness and high wear resistance, good chemical stability and extensive compatibility characteristics, is widely applied in the metal cutting processing field. The author mainly studies the cutting force contrast between coated carbide cutting tools and not coated ones. Cutting tests have testified that if PVD technology applied on cutting, the cutting force of hard alloy cutter will alter with the change of feeds (f), depth of cutting (ap) and cutting velocity (v). The experiment suggests that the size of three-way cutting force of either the brand ZP25 hard alloy cutter or the carbide cutter by employing matrix ZP25 hard alloy cutter to respectively using PVD technology coat TiN or TiCN coating is successively FZP25>FTiCN>FTiN. The main reason for this is that the difference of frictional factor of the three kinds of cutter material and the workpiece material.

Abstract: The evolution of carbon/epoxy composites use in aeronautics requires a better comprehension of the machining conditions influence on these materials. This study aim is to establish, based on the experimentation, the relationship between machining conditions and the behavior of drilled 2D and 3D carbon/epoxy composites. Two drill geometries, seam introducing and a range of cutting speed and feed have been tested. The effect of each parameter has been assessed in terms of thrust force, moment (recorded during machining) and defects (performed by macroscopic analyses and quantified using delamination factor F_d). Experimental results have shown significant influences of feed and drill geometry on delamination reduction. The use of a spur drill and a low feed generates minor defects and produces the best results. Furthermore, stitching helps reduce damage inside the hole.

Abstract: The demand of carbon fiber reinforced plastics (CFRP) has been increased in aircraft and automobile industries. In milling of CFRP, the cutting parameters should be determined to finish the machining surfaces without delamination. The tool wear is also a critical issue to finish good surfaces. The paper presents a force model to study the milling process of CFRP. In order to investigate the anisotropy in milling of CFRP, the cutting tests were conducted for unidirectional CFRPs with changing the feed direction of the milling tool. The cutting force and the surface finish depend on the feed direction with respect to the fiber orientation. A force model based on the minimum cutting energy is applied to milling of CFRP. The orthogonal cutting data used in the force model is associated with the relative angle of the cutting edge rotation angle to the fiber orientation. The model was verified in comparison between the predicted and the measured cutting forces. The model also estimates the effect of the feed direction with respect to the fiber orientations on the cutting force in terms of anisotropy in the orthogonal cutting data.

Abstract: In order to understand the problems that arising during machining and contribute to find the best way to produce medical prosthesis, an experimental milling analysis was conducted in Ti-6Al-4V and Co-28Cr-6Mo alloys. The thermal gradient and the cutting forces created on the surface during the machining were evaluated for different cutting speeds. Moreover, the roughness and Vickers hardness were evaluated. Based on the results obtained, it is possible to conclude that the difficult to cut of Co-28Cr-6Mo alloy is higher than Ti-6Al-4V alloy.

Abstract: Bionics research finds that the non-smooth morphology surfaces of some typical animals can reduce the forward resistances in the movement process. We can imitate these characteristics to reduce the machine tool wear during the machining process, which greatly promotes the machining and production procedure. Using the finite element simulation method, the effect of TC4 bio-mimetic wear-resistant cutter on cutting force, cutting temperature and micro-process were researched in-depth. The results verified the effect of bionic wear-resistant tool on the anti-friction process of metal cutting. On the other hand, we discussed the relationship between the effect and parameter of the tool surface non-smooth morphology is not smooth. Also, this paper revealed the basic principles of bionic wear-resisting tool anti-friction, which provides guidance for the selection of non-smooth morphology.

Abstract: Through experiments and orthogonal regression, the cutting force model of machining bars on a CNC lathe HCK60 equipped with the Huazhong CNC system is established. The model is simplified by using the knowledge of matrix theory, and we got the cutting force prediction empirical formula. The verifiable experiments show that the errors between predicted values and measured values are almost within 10%, which validates its high credibility. In addition, it can provide boundary conditions for the finite element analysis of CNC machining deformation, which is very important for application value.

Abstract: This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.