Papers by Keyword: Cutting Force

Abstract: This analyses evaluates the cutting force , surface roughness, chip morphology, chip–tool interface temperature, tool life, and Single use of a coated carbide tool and double liquid nitrogen jets for friendly superalloy that is extremely difficult to cut being turned (Ti-6Al4V). The rake face was the only focus of the single jet, while the rake and flank surfaces were concurrently hit by the duplex jets. Liquid nitrogen jets provided the highest machining quality, reducing cutting force , temp, hardness, and, apparently, tool life. When equated to dry and single jet assist, the double liquid nitrogen jets increased life of the tool by 60% and 30%. In spite of this, chip manufacture has not changed. Using duplex liquid nitrogen jets to extend tool life, reduce tool costs, lower temperatures, improve surface quality, and most importantly, promote machinability of Ti-6Al-4V superalloy has been accepted as a sustainably booster.

Abstract: Metal cutting is the way of processing the workpiece with tool having sharp cutting edges of different materials generating chips of different shapes and sizes. In present era of industry 4.0, metal machining should not be unrated during processing of hard grades metals and superalloys where large amount of cutting forces are generated. Also, the measurement of cutting forces provides the basic of economical machining and hence accurate evaluation in experimental and analytical manner has great importance. The traditional models of metal cutting have disagreement with experimental results due to missing of important mechanics terms. With the development of digital technology, the errors in calculation of cutting force have also been shortened due to consideration of terms absent in conventional models. In present investigation, the cutting forces have been evaluated experimentally using dynamometer and analytically with Astakhov’s methodology during turning of EN-31 steel. The results revealed that 12.9% observations have deviation more than 20%, whereas 16.67 % has zero deviation. Further, the feed rate has more influence on cutting forces as compared to speed and nose radius. In addition, the minimum quantity lubrication (MQL) of vegetable oil has lowered the cutting forces appreciably compared to dry machining.

Abstract: Flat bottom drills at a point angle of 180 deg. have recently been applied to not only drilling on inclined surfaces but also flat bottom holes in terms of the dimensional accuracy and the process efficiency. Controlling the cutting force, the tool damage, and the surface finish, the corner shape is a critical parameter in the design of the flat bottom drill. The paper discusses the effect of the corner radius on the cutting forces and the surface finish in drilling with flat bottom drills. The typical differences in the cutting force are confirmed during the edge engagement. Then, the cutting force is simulated with a chip flow model, in which the chip flow angle is determined to minimize the cutting energy. The cylinder surface finishes and the burr formations are associated with the chip flow direction and the uncut chip thickness at the end of the lip.

Abstract: A CNC dry milling experiment was conducted for the machining parameter optimization of two grades of Martensitic Stainless steel (MSS). Optimization is done by employing Taguchi method (S/N ratio and ANOVA). The specimens used are MSS grades 410 and 420.The experiments were designed by employing L₉ orthogonal array for 3 levels of feed and spindle speeds. The impact of these parameters on cutting force was analyzed. The analysis reveals that spindle speed constitute the maximum impact on cutting force for both MSS grades. Optimum cutting parameters are obtained at 30 mm/min (feed rate) and 1500 rpm (spindle speed). Due to higher Chromium and Carbon content in AISI 420 MSS resulted higher cutting force values compared with AISI 410 MSS. Optimum values of cutting parameters are estimated for improving productivity and quality. The predicted values at optimal conditions are estimated. The results indicate a good conformity with the outcome of experiment.

Abstract: The purpose of this work is to increase the productivity and accuracy of processing long-length parts of the "shaft" type on CNC machines. Based on the analysis of existing methods for improving the accuracy of processing long shafts on CNC machines, a new method for controlling the spatial error of processing long shafts by changing the processing modes was proposed. The proposed method allows, by changing the processing modes, namely feed, to reduce the radial component of the cutting force and reduce the amount of deflection when machining parts on CNC machines. A technical and economic analysis and justification of scientific research was carried out. The economic effect of the proposed method.

Abstract: Despite the advanced development in the field of creating new hard-alloy and ceramic tool materials, the use of modern high-speed steels has not yet lost its relevance, and it is especially true for the production of small batches of costly specialized tools, especially since modern strengthening technologies can make it competitive. For example, additive production systems associated with laser or electron beam manufacturing methods create products, including Ti-6Al-4V alloy, with low surface quality, and it is still necessary to apply the additional cutting treatment. The features of milling titanium alloy obtained by the electron beam melting method were revealed. It is determined that the force parameters differ from those in the processing of metal obtained by traditional technologies. Thus, the component of cutting tangential force F_T increases by approximately 15%. At the same time, a 20% drop in the radial force F_R observed

Abstract: Formation of roughness during treatment by polymer-abrasive brushes occurred as a result of interaction of cutting micro-relief with processed surface. The cutting micro-relief of abrasive instrument is described in the form of random process with normal distributional law. When calculation of roughness, the depths of penetration of cutting lugs in processed material as well as regularity of changing of radial radius of rounding of peaks of cutting lugs from modes of treatment are taken into consideration. Set are relations of roughness of processed edge from modes of treatment (deformations of instrument, cutting velocities, feeding) as well as from constituent cutting force. It is proved that usage of polymer-abrasive brushes for rounding of edges faces all requirements of aviation industry on roughness of processed edges.

Abstract: The milling experiments were conducted carried out which Ti-6Al-4V alloys with different amount of hydrogen permeating were processed, in order to explore various problem in the machining process of hydrogenated titanium alloy. The main cutting force, microhardness and residual stress before and after milling were measured. The experiments result show that Ti-6Al-4V alloy with appropriate amount of hydrogen can effectively reduce the cutting force, improve the surface hardness and reduce the surface residual stress.

Abstract: Cutting force and cutting temperature are two important parameters in the cutting processes. In this paper, AdvantEdge finite element analysis software was used to simulate and analyze the reaming process of aviation aluminum alloy 7050 by using PCD reamer. The cutting simulation model was established to investigate the effect of spindle speed, feed per tooth on thrust force and cutting temperature. Simulation results showed that the cutting force increased with the increase of feed per tooth at different spindle speeds. And in the case of different feed per tooth, the cutting force decreased slightly as the spindle speed increase. Besides, from the cutting temperature distributed in the reamer, the cutting temperature near the tip of the tool in the reaming process was highest, the cutting temperature increased with the increase of both spindle speed and feed per tooth.

Abstract: Machining is one of the major manufacturing processes that converts a raw work piece of arbitrary size into a finished product of definite shape of predetermined size by suitably controlling the relative motion between the tool and the work. Lately, machining process is shifting towards high speed machining (HSM) from conventional machining to improve and efficiently increase production, and towards dry machining from excessive coolant used wet machining to improve economy of production. And the tools used are mostly hardened alloys to facilitate HSM. The work piece materials are continually improving their properties by emergence and development of newer and high resistive super alloys (HRSA). In this paper an attempt has been made to validate an experimental result of cutting force obtained by performing HSM on an HRSA Inconel 718, by comparing it with the numerical result obtained by simulating the same setting using DEFORM 3D software. Based on the comparison it is found that the simulated results exhibit close proximity with the experimental results validating the experimental results and the effectiveness of the software.