Papers by Keyword: Chip Breaking

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Authors: Somkiat Tangjitsitcharoen
Abstract: This research presents the chip breaking detection system by monitoring the cutting temperature during the in-process turning. The effects of cutting parameters on the cutting temperature and the chip formation are investigated. The in-process monitoring of chip formation is developed to detect the continuous chip, the mixed chip and the broken chip by utilizing the ratio of the maximum variance of the dynamic cutting temperature to the average variance of the dynamic cutting temperature. The broken chip formation is required for the reliable turning operation. The new algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process referring to the cutting temperature. It has been proved by series of cutting experiments that the broken chip can be well identified by the proposed method.
Authors: Kitikun Klungphon, Somkiat Tangjitsitcharoen
Abstract: In order to realize the intelligent machines, an in-process monitoring system is developed to detect the continuous chip and the broken chip regardless of the cutting conditions on CNC turning by utilizing the power spectrum density, PSD of dynamic cutting force and the variance of the dynamic cutting temperature, which are measured during the cutting by employing the dynamometer and the infrared pyrometer. The broken chip formation is required for the reliable turning operation. The preliminary experiments suggested that there are basically two patterns of PSDs of chip forms. One is the case of relatively high PSD of the dynamic cutting force at low frequency range, which corresponds to the continuous chip formation. The other is the case of relatively large PSD of the dynamic cutting force observed in a frequency range corresponding to the chip breaking frequency when the broken chip are formed. The variances of the cutting temperature are also significantly different between the broken chip and the continuous chip. Hence, the method has been developed by using the PSD of dynamic cutting force and the variance of cutting temperature to determine the proper threshold values for classification of the broken chip and the continuous chip during the cutting. The new algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process. It has been proved by series of cutting experiments that the broken chip can be well identified by the proposed method even though the cutting conditions are changed.
Authors: Ai Dong He, Bang Yan Ye, Zi Yuan Wang
Abstract: Cryogenic MQL is a kind of green machining technology of the combination of cryogenic air and minimal quantity lubrication (MQL). The aim of this research is to determine if the cryogenic MQL technique in turning with Cutting tool with internal cooling structure gives some advantages in terms of tool life, surface roughness and cutting chip breaking. This paper reports the results obtained from turning tests, at one feed rates (0.12mm/r) and one depth of cut (0.4mm) and different cutting speeds (43m/min, 108m/min, 217m/min), and the results obtained show that using cryogenic MQL had some advantages in terms of tool wear, surface roughness and cutting chip breaking compared to using dry cutting and cryogenic air cutting. And the results obtained show that when cryogenic MQL and cryogenic air cutting were applied to high speed cutting, they had more advantages.
Authors: Guang Yu Tan, Guang Jun Liu, Guang Hui Li
Abstract: The Movable Cellular Automata (MCA) method is introduced into the analysis of cutting process, and is employed to build the discretised MCA tool-chip model of orthogonal cutting. The chip breaking and curling rule are proposed to determine the MCA local rule. The simple local rule and discretised method are presented to describe the continuous process of chip’s formation and breaking. The states’ rule of a cell and its neighbors can be used to predict and calculate the chips’ breaking and curling. The numerical calculation and a numerical example in the process of chip breaking and curling are proposed.
Authors: Xin Min Feng, Guang Yu Tan
Abstract: BP neural networks model which was used to predict the rang of breaking chip of 3D complex groove turning inserts was established, then training and testing of the network was realized with MATLAB, finally ,range of breaking chip of the insert which was designed by the author was predicted. Percentage of accuracy of predicting results reached 91.67% comparing with the chip breaking experiment. This indicates that neural networks can be used to predict rang of breaking chip of turning inserts, so, saving the inserts which is used for cutting experiments and work of experiments, reducing the periodic time of inserts designing and development, increasing the competitive strength of inserts.
Authors: Peng Zhang, Xing Yu Guo, Kang Pei Zhao, Li You Zhu
Abstract: It is often one of the most important issues for chip breaking and chip removal problems in the hole machining process, especially for micro hole. The chip breaking mechanism of the vibration drilling is researched, and its chip breaking conditions is analyzed. The micro drilling experiments are carried to contrast the chip shape of common drilling and vibration one. It can be draw that the vibration drilling can realize the regular chip breaking, which is beneficial to chip removal in hole machining, the chip breaking feature is one of the fine process effects. This work further enriches the vibration drilling technology.
Authors: Er Liang Liu, Yu Fu Li, X.Z. Wang, Fei Xiao, Xian Li Liu
Abstract: In the process of turning high-temperature and high-strength steel, it is an effective method for chip breaking with complicated groove insert. In this paper, chip breaking mechanism is analyzed using the coated complicate groove insert for cutting high-temperature and high-strength steel. The model of chip curl radios is constructed though analyzing the effect of complicated groove insert on chip formation. The mathematical formulation of chip section profile coefficient is built through analyzing influential effect of complicated groove on chip section profile. The chip breaking model is developed according to chip-breaking criterion. Finally, a full experimental validation of the model is presented for chip breaking when the workpiece is high-temperature and high-strength steel, 2.25Cr-1Mo-0.25V. The tested results show the chip breaking model is reasonable, and the optimization cutting parameters are obtained.
Authors: Hui Ping Zhang, Fu Gang Yan, Yan Xin Wang, Yuan Sheng Zhai, Xian Li Liu
Abstract: Firstly, with studying three typical aspects as cutting force, cutting temperature and chip breaking behavior, contrast experiments of machinability were made on hydrogenated cylindrical shell materials (2.25Cr-1Mo-0.25V), 45 steel, and stainless steel (1Cr18Ni9Ti). The experiment results show that the depth of cut ap have a larger effect on the main cutting force FZ and the cutting temperature θ than the affection of the feedrate f, for that reason, in order to reduce the main cutting force FZ and the cutting temperature θ, large feedrate situation will be better for machining work of hydrogenated cylindrical shell materials. When cutting hydrogenated cylindrical shell materials , many difficult points appearance, such as large cutting force, high cutting temperature, serious chips winding, chips difficult to break etc, which has worse machinability even than stainless steel(1Cr18Ni9Ti).
Authors: Ming Yang Wu, Bo Wang, Yao Nan Cheng, Y. Tian, Yong Bin Gao, F.G. Yan
Abstract: Large cylindrical shells are widely used in many areas of aerospace, petroleum chemical industry and nuclear power, etc. The main material of large cylindrical shells is 2.25Cr-1Mo-0.25V. In the process of heavy-duty cutting cylindrical shell material, the removal rate is high, and machine condition is rough, because the viscosity of big cylindrical shell material, the large chips not easy to be broken, and the tool and workpiece often entangled affect the machining efficiency. Researh and development to apply heavy cutting under the condition of high performance cutting tool has great practical significance, because of at the same time for heavy cutting tool is less in china. This paper uses the cutting performance experiment aiming to cylindrical shell material used in different three-dimensional groove blades and studies the range of different blades broken chips and the influence of three-dimensional groove on breaking effect. The chips form of cutting cylindrical shell material is summarized. And chip-breaking groove of the best performance is optimized. The paper designs of the new heavy-duty vehicles blade well and vertfies the good effect of the new heavy-duty cutting the breaker by the results of 3 d finite element simulation. The paper provides basis for designing heavy-duty cutting.
Authors: Qing Yan Ma, Biao Wang, Da Guo Yu
Abstract: In the drilling process for deep hole, the continuous chips often jam up due to the difficulty of chip removal, and the chips cause problems such as tool breakage and deterioration of the surface quality. The measures of chip removal must be adopted, especially for small diameter deep hole, the chip removal space is limited and thickness and length of chips can directly influence the chip removal, the chip size are required as a precondition for chip removal. In this study, the feed is periodically varied in numerical control machine, and the length of chip can be controlled, then the chip breaking is realized with no addition special chip breaking mechanism, which combines with negative pressure suction mechanism for chips, and solves the problem of chip breaking and removal.
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