Papers by Keyword: Oblique Cutting

Abstract: This paper examines whether the Coupled Eulerian-Lagrangian formulation, combined with a thought-out 3D geometry, used recently in turning processes, can provide accurate simulation results. Oblique cutting cases were analyzed with the aid of commercial software for Finite Element analysis. An evaluation of the simulation results was performed by comparing the cutting forces and temperatures of the simulation with experimental turning results. Overall, simulation results with good correlation with experimental data were observed for cutting forces, including axial force distribution and temperature prediction, showing that this approach can be used in turning simulations, regardless of cutting conditions involved.

Abstract: Machining has been one of the most sort of process for realizing different products. It has significant role in the value additions process. Machining is one of the production process where material is removed from the parent material to realize the final part or component. Among machining, the well known machining processes are turning, milling, shaping, grinding and non-conventional machining processes like electric discharge machining, ultrasonic machining, chemical machining etc. The fundamental of all these processes being material removal in the form of chips using a tool either in contact or not in contact. In the present work, milling is being taken for study Finite element analysis is being used as a tool to understand the different phenomenon that underlies the machining processes. Of late, the machining induced residual stresses is of great interest to the researchers since the residual stresses have an impact on the functional performances. The present work is to model the milling process to predict the forces and residual stresses using finite element method. Unlike many researchers, the authors have attempted to develop oblique cutting model rather than an orthogonal cutting model. The present work was carried out on AISI 1045 steel.

Abstract: An optimization method of end mill geometry parameters is presented for minimizing cutting energy. The helical end mill geometry is established at first. Then, the helical flutes are decomposed a set of infinitesimal oblique cutting edges. At every oblique cutting element, the differential cutting energy, which consists of differential shear energy and differential friction energy, is calculated using oblique cutting theory. By integrating the differential cutting energy along each cutting edge in the end mill, the cutting energy can be predicted during end milling. The effects on cutting energy of end mill geometry parameters are analyzed. Finally, the end mill geometry can be optimized in order to minimizing cutting energy.

Abstract: A unified oblique cutting force model for flat end mills is developed. In this model, the cutting force is bridged among cutter geometry, material properties and cutting parameters. The cutter angles, material parameters and cutting parameters are the only inputs so that the model is applicable for different cutter-workpiece combinations and cutting parameters. The parameters in the model are solved by the geometric relations, applying Maximum Shear Stress Principle and Stabler’s chip flow rule. The material parameters are identified in a new method with orthogonal milling tests. The simulation results of the proposed model are in good agreement with experiments.

Abstract: The article discusses contact interaction of the straight-edge or radius cutter with the workpiece. Parameters under investigation are as follows: geometry in a setting system, the cutting edge length and a cross section of the shear layer. The description of the main features of the straight-edge cutters is given. Characteristic curves of parameters under investigation are presented. Guidelines for choosing of cutting tools are offered on the basis of the data obtained.

Abstract: The article presents a method for constructing a three-dimensional model of the equivalent wedge oblique cutting edge. This technique allows you to visually assess the complexity of changing the geometry of the tool and can be used in the design of cutting edge with a curved wedge. To construct a model, the equation of a space curve of cutting edge working part was derived. The article also shows the position of the tool-in-hand and the setting system in the developed model.

Abstract: In recently years, researches about round-hole broaching mainly focus on broach macro environment and industry structure. However, researchers study little from technical level. We aim at simplifying broaching process of worm gear round broach into rectangular and oblique cutting process. In the same conditions, we make use of finite element analysis software for stress analysis of two kinds of cutting mode broach, to provide a certain theoretical basis for using tool reasonably and tool parameters optimization design in the production.

Abstract: Paper show possibilities to optimization of exploitation process of single edge tools. It decrease cost of machining using optimizing the use of the cutting edge. This possibility was presented for single edge tools in oblique and orthogonal cutting. In oblique cutting was presented optimizing the use of the cutting edge by partially exchange of active section of the cutting edge. It is shown for straight edges. Presents model of special tool and result of made experiments, which shows possibilities to increase tool life. Second presented possibilities is orthogonal cutting with round insert. Presented results of calculations of number cutting edges from one round insert by optimizing the use of the cutting edge. For orthogonal cutting was used normal market construction tools for round inserts. Presents first results of surface roughness for tools with worn up cutting edge and rotate for exchange this worn up fragment of cutting edge. In this case number of edges cutting insert increase many times. This can many times reduce the cost of tools in cutting especially in turning.

Abstract: Based on finite element software DEFORM-3D, a three-dimensional oblique cutting model for aerospace aluminum alloy was built. The material’s flow stress behavior was described with Johnson-Cook constitutive equation. The separation of the chips with the workpiece was realized by the combination of adaptive remeshing technique and separation criterion. The material’s failure was defined by adopting Cockcroft & Latham fracture criterion. The tool-chip friction model was the combination of a Coulomb friction model and shear (sticking) friction model. To validate the finite element model, cutting tests were conducted. The effects of tool geometrical parameters such as flank wear, cutting edge inclination and corner radius on cutting forces were analyzed by three-dimensional oblique finite element model.

Abstract: Aimed at the design of the radius of flute for solid carbide end mill, a new oblique cutting model for milling was established based on the simplified model of milling layer. Depending on this model, an equation was developed to calculate the maximum chip thickness in milling. An oblique cutting simulation via FEM(Finite Element Method) was conducted to verify the equation. The conclusion was that the result gained from the simulation was in a good agreement with the present model, so the present model is reasonable to predict the maximum chip thickness in milling and to determine the radius of the arc at the bottom of the flute.