Papers by Keyword: Cutting Force

Abstract: This study aimed to achieve superior sealing surface quality through a cutting process utilizing a non-rotational cutting tool. Previous research has explored the suppression of chatter vibration using indexable non-rotational cutting tools fabricated from damping alloys. The experiments employed a custom indexable tool composed of a damping material (M2052), with cemented carbide as the insert material. Prior research has indicated that non-rotating cutting tools incorporating damping alloys exhibit enhanced suppression of chatter vibrations, compared with traditional non-rotating tools. This study extends the enquiry to assess the effects of the cutting edge shape on the stability of cutting operations using non-rotational cutting tools with damping alloys. To investigate the effect of the cutting-edge shape on the machined surface, the cutting forces were measured using a dynamometer, the machined surface was measured using a white light interferometer, and the residual stresses were measured using an X-ray residual stress analyzer. Consequently, the insert with a large cutting width had a large variation in the cutting force and caused the generation of compressive residual stress, depending on the conditions. However, it is clear that the insert with a small cutting width exhibited a small variation in the cutting force and generated tensile residual stress, resulting in stable cutting.

Abstract: This study aims to investigate the effects of Minimum Quantity Lubrication (MQL) independent pulse parameters, which are the intervals between two pulses (1, 2, and 3 seconds) and the duration of the lubricant application (1, 2, and 3 seconds), in the turning of AISI 1040 steel. MQL pulse parameters supplying the best lubrication in terms of cutting force, cutting temperature, and surface roughness were 1 second interval between pulses and 3 seconds duration of lubricant application. These parameters provided 10.7%, 43.6%, and 65.5% improvement in cutting force, cutting temperature and surface roughness values, respectively, compared to dry cutting conditions. When the MQL pulse parameters were compared among themselves, an improvement of 6.7%, 38.3% and 61.7% was achieved in the cutting force, cutting temperature, and surface roughness values, respectively, in the conditions that gave the worst and the best results. According to ANOVA (Analysis of variance) results, the duration of the lubricant application was determined as the most important parameter on the surface roughness and resultant force whereas the interval between two pulses was obtained the most important parameter on the cutting temperature.

Abstract: One of the critical aspects in performance optimization of energy efficiency for a Brushless DC (BLDC) motor applied to hedge cutters is that of cutting force versus current consumption. The mechanical cutting force produced during the hedge cutting operation will be presented, here, in a manner relating to the electrical current drawn by the BLDC motor. It indicates that the cutting forces depend on the blade's sharpness, the density of the material, the speed of cutting; and that the current consumed by the motor is directly proportional to the value of this cutting force. The outcome of this study reveals that motor current monitoring performs favorably as an alternative measurement of the resistance of cut and mechanical load in real-time, seeking to enable the implementation of intelligent systems for performance optimization and predicting maintenance. The findings from this will also be beneficial in designing energy-efficient motors for custom-made cutting conditions and thus increase the overall robustness and cost-effective aspects related to operation of hedge cutters. A more accurate representation of this relationship can be refined through further research focusing on material properties and motor control algorithms, allowing for better use of energy and more precise control of horticultural implements. The aim of this paper is to investigate the relation between the different cutting forces occurring during the hedge trimming process and the current consumption of the BLDC motor. The paper will approach this question from a theoretical (calculation and simulation) point of view.

Abstract: Tool life is recognized as a critical factor in finishing a fine surface as well as high machining accuracy in cutting operation. The tool wear progress, therefore, should be evaluated in cutting simulation before the operation. This paper presents an analysis of tool wear rate during a rotation of tool in fly cutting as a manner of gear machining. The distribution of tool wear rate is analyzed with the stress and the temperature on the rake face based on a tool wear characteristic equation. The cutting force is estimated in a chip flow model, which piles up the orthogonal cuttings in the plane containing the cutting and the chip flow directions. The chip flow direction is determined to minimize the cutting energy. Then, the cutting temperature is analyzed numerically in the finite volume method, where the mechanical energy is converted to the heat generation in the shear zone and the rake face. In the fly cutting, the stress and temperature change with the uncut chip thickness and the tool-chip contact area during a rotation. Therefore, the instantaneous tool wear rates are analyzed for the rotation angles by the stress and the temperature distributions. This paper demonstrates an example of the tool wear analysis in cutting processes of a carbon steel. A cutting test was conducted to identify the force model with the orthogonal cutting data used in the analysis. Then, the temperature and tool wear distributions on the rake face are analyzed with the uncut chip thicknesses and the tool-chip contact areas.

Abstract: Boring process, also referred to internal turning, is commonly used to machine critical features of landing gear components like struts, brackets, and main cylinders. Over the past years, extensive research efforts have addressed the stability of the process by developing instrumented boring bars and advanced monitoring techniques. However, although the surface integrity characteristics, particularly the residual stresses, are crucial for structural components, it hasn’t been considered and its evolution over the boring conditions still not well understood. Hence, the present paper proposes a comprehensive investigation on the effects of boring conditions on the surface integrity of the aluminum alloy 7175-T74 commonly used in landing gear components. A parametric analysis has shown that lower cutting forces and surface roughness can be achieved using a larger insert nose radius. It was also found that feed rate, cutting speed and depth of cut experienced strong interaction effects with the machining mode (dry/wet) regarding the resultant cutting force and surface roughness. Results have also shown that wet boring conditions generated compressive residual stresses. An optimal boring condition was obtained using Grey relational analysis (GRA) – Taguchi method. Further investigation is required to refine the obtained optimal machining condition by considering the GRA results and the parametric analysis outcomes.

Abstract: This study focused on cutting trace control for machining three-dimensional contours, such as molds, with high accuracy and efficiency. In this study, experiments were conducted to generate a honeycomb structure with hexagonal cutting marks and a lattice structure with square cutting marks in the cutting process of a two-blade ball-nose end mill using a runout adjustable holder, with the aim of adapting the cutting-mark control to the production level. In this study, the relationship between runout, machined surface, and cutting force is shown, and the effects of runout, honeycomb structure, and lattice structure on surface adsorption are investigated and evaluated for applications in the production field.

Abstract: The paper presents a mathematical model for calculating cutting forces during the machining of 16MnCr5 steel using the Sandvik CNMG 120408 16P25T tool. The modeling process involved the use of a test rig constructed based on the 16Д25 machine, which enabled the measurement of real values of spindle speed, longitudinal feed, cutting depth, and cutting forces. The results transmitted to a computer through the LTR-EU-8 workstation, equipped with galvanic isolated LTR modules and a synchronization interface. Based on the experimental results, the theoretical model demonstrated a deviation from actual measurements of no more than 4.72%. The study provides evidence that the cutting force calculations commonly presented by leading tool manufacturers are inherently overestimated. he difference in cutting forces can be 9%.

Abstract: Traditional manufacturing and finishing operations of crystal products use intensive specialized labour resulting in high cycle times and production costs. It is intended to investigate the applicability of automated finishing technology, namely grinding in a CNC machining centre, with consideration of material’s characteristics and geometric variability to crystal processing. A case study will be presented, involving cutting tools development, cutting parameters optimization, CAM programming of machining strategies and toolpaths, product clamping systems and finally product machining and quality control that is being implemented at Vista Alegre Atlantis company.

Abstract: In this research work, was made a study on the effects of turning conditions on incoloy 901 nickel-based superalloy and performed a precision analyzes using the Taguchi L27 orthogonal array. Using the results of variance analysis (ANOVA) and signal-to-noise (S / N) ratio and taking into account the "smaller is better" approach were statistically investigated to establish a correlation amongst the speed of cutting, feed rate and cutting tool with respect to surface quality and cutting forces. KCU10, K313 and KCU25 cemented carpide cutting tool were used in experimental study. The experimental results have revealed the most important factor influencing the cutting force and surface quality was the type of the cutting tool and it’s had a serious effect on both, KCU10 and followed by KCU25 was found better than the other cutting tool. Optimum parameters for the cutting forces were found 0,150 mm/rev., 90 m/min. with KCU10 cutting tool The found findings can help for revealed the optimization of machining parameters and surface characteristics of Incoloy 901 during high speed turning.

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.