Papers by Keyword: Orthogonal Cutting

Abstract: The research presented in this paper refers to the study of the influence of feed and cutting speed on the cutting forces, temperatures and chips formation in turning of AISI 1045 carbon steel and AlSi1MgMN aluminium alloy. This work presents both finite element simulation and experimental tests. Parameters have been considered variable in the process are cutting speed and feed, and depth of cut and tool geometrical parameters were kept constant. The purpose of the experimental procedure it was the acquisition data for cutting forces and temperatures by on-line monitoring, with KISTLER dynamometer for cutting forces and Flyr System ThermaCAM SC640 termography camera for temperatures. Both results obtained by finite element simulation and experimental tests show that the feed increasing lead to increased cutting forces and temperatures. Also, are presented the type of the chip obtained in orthogonal cutting of the two materials.

Abstract: In this paper the modelling and simulation of nanometric cutting of copper with diamond cutting tools, with the Molecular Dynamics method is considered. A 2D model of orthogonal cutting, with nanoscale features, is constructed. In this model two different potential functions to simulate the interaction of the atoms within the workpiece and between the workpiece and the tool are used; LennardJones potential for the former and the Morse potential for the latter case. From the simulation the chip formation can be observed and analysed. The model is used for the simulation of nanocutting with three different nanometric depths of cut from which the cutting forces are calculated and compared. With increasing depth of cut, cutting forces also tend to increase. The proposed model can be successfully used for the modelling of cutting operations that continuum mechanics cannot be applied or experimental and measurement techniques are subjected to limitations or it is difficult to be carried out, such as ultra-precision machining, micro-cutting, miniaturization and nanoscale cutting.

Abstract: In view of orthogonal cutting, finite element simulation geometry is built. the friction model, thermal conduction model and chip separation model are established between chip and tool using Abaqus which is a finite element analysis software. Through a specific example, two-dimensional finite element model have been established, simulating the cutting process stress distribution of the work piece surface is also obtained during processing. While simulation analyzes the relationship between the rake angle and shear angle, the results of simulation and experiment are basically the same, thus further verify the credibility of Abaqus simulation results on orthogonal cutting, and the feasible is also proved of obtaining cutting data by the use of Abaqus simulation cutting process.

Abstract: Hardened steel, Ni-based alloys and brittle materials are very difficult to machine using conventional cuttingmethods.A tool edge with a small nose radius can alleviate the regenerative chatter. In general, it is important for conventional cuttingto use the smallest possible tool nose radius. A sharp tool shape has an adverse effect on tool strength and the instability of machining process still occurs. A tool wear model with small nose radius proposed by past researchers is evaluated for predicting metal cutting tool wear when machining the copper. Tool temperature values are determined using finite element methods simulation. These temperatures are related to tool wear measured after metal cutting turning tests on a copper workpiece to determine tool edge geometry in low metal tool model.In this study, the effects of cutting conditions and tool edge geometry on process stability in turningare investigated through experiments and FEM simulations.

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: This paper develops a 2D finite element model for the enhanced cooling cutting of stainless steel. The enhanced cooling effect is modeled with a convective heat transfer coefficient assigned to a heat transfer window of cutting zone. Five convective heat transfer coefficients are defined to simulate different enhanced cooling effects. The simulation results suggest that increase of convective heat transfer coefficient results in a very small reduction of maximum tool-chip interface temperature, even when a very large convective heat transfer coefficient is used. In addition, no significant effect on cutting force and thrust force is observed with the increase of convective heat transfer coefficient.

Abstract: Bone machining processes are often performed in orthopaedic surgery and dental implantation, yet its analytical study is lacking. Towards contributing analysis on bone machining, this study reviews available references on orthogonal machining of bones. Considering the allowable limit in temperature and duration during bone machining to avoid thermal necrosis, machining temperature and forces are the machining responses of interest. Machining conditions (cutting speed, depth of cut, cooling method, tool geometry, and cutting direction) are analyzed in term of their effect to those machining responses.

Abstract: A two-dimensional macro-mechanical finite element (FE) model is developed to study the orthogonal cutting process of CFRP unidirectional laminate by the finite element software ABAQUS. The CFRP laminate is defined as an equivalent orthotropic, homogeneous single-phase material. On the basis of composite unidirectional laminate plane stress-strain and strength theory, the author adopts Hashin progressive damage criteria in the FE model. Based on the results of finite element simulation, the changes of cutting force in the chip formation process of CFRP laminate are analyzed, the Hashin damage in the cutting process and the influences of fiber orientation on cutting force, chip formation mechanism and sub-surface damage are explored as well. The comparison between this paper and previous related research shows that the results have a reasonable agreement with the previous achievements.

Abstract: Currently biomimetic tribology study shows that high performance surface texture can achieve good friction, anti-adhesion and improve the wear resistance, which brings a new research direction for tool antifriction technology. The orthogonal cutting tests of surface micro-groove cutting tool in machining titanium alloy were presented. Different types of micro-grooves were made using laser in the rake face of uncoated tungsten carbide cutting inserts. Dry with no lubricant and minimal quantity lubricant (MQL) were used as lubrication conditions. Cutting force and cutting temperature were measured and compared. It was found that under MQL condition the surface micro-grooves could effectively improve the friction status between the tool and chip, thereby reducing cutting force and cutting temperature, and also reduce cutting temperature under no lubricant condition. The micro-grooves paralleling with cutting edge had the best effect in three types of micro-grooves.

Abstract: Material constitutive equation plays an important role in Finite Element Analysis (FEA) of metal cutting process. This paper proposes a method to obtain parameters for Power Law model of a Japanese type of alloy steel (SCM440H) for 3-D FEA of face milling process, involving pressure bar experiments and orthogonal metal cutting experiments. Since pressure bar test cannot reach the high strain rate occurred in cutting process, orthogonal cutting experiment was combined to obtain parameters for material model. By this method, the ideal parameters for FEA of the face milling process were finally determined. Face milling experiments were performed to verify the accuracy of the model built.