Papers by Keyword: Cutting Force

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Authors: Khurshid Alam, Riaz Muhammad, Vadim Silberschmidt
Abstract: Bone cutting is a well know procedure in orthopedics. Large cutting force causes overstressing of the bone which may result in trauma. Control penetration of the cutting tool into bone tissue is important to avoid unnecessary damage to the bone tissue. The purpose of this study was to measure and predict cutting force using experiments and Finite Element (FE) analysis when a plane cutter passes over the bone surface in the presence of irrigation. The effect of cutting speed, tool rake angle, depth of cut and width of the cutting face on the cutting force was found. The force was found to decrease with increase in rake angle and significantly rise with increase in depth of cut and width of cutting face. The cutting force was found unaffected by the range of cutting speed used in experiment as well as in simulations. The results obtained from this study strongly recommend the use of irrigation to minimize plane cutting force or force arising from similar cutting action for safe and efficient surgical incision in bone.
Authors: Nik Masmiati Nik Pa, Ahmed Aly Diaa Sarhan, Mohd Hamdi Abd Shukor, Mohsen Abdelnaeim Hassanim Mohamed
Abstract: Milling is a machining process by which a surface is generated by a progressive chip removal. An experimental investigation has been carried out on the performance of up and down milling under dry and flood conditions when end milling medium carbon steel utilizing titanium coated carbide tools. The performances are evaluated in terms of the cutting force, specific energy and power of cutting tool. The results show that milling in dry condition under up milling mode produce higher cutting force, specific energy and power. However, cutting under down milling mode gives less significant effect either being cut in dry or flood condition.
Authors: Tao Wu, Kai Cheng
Abstract: Modelling and simulation of the micro milling process has the potential to improve tool design and optimize cutting conditions. This paper presents a novel and effective 3D finite element (FE) based method for simulating the micro milling process under large deformations. A tooling model incorporating a helix angle is developed for cutting forces, tooling temperature and chip formation prediction. The proposed approach is experimentally validated and the simulated micro milling performance such as micro chip formation and cutting forces are in reasonable agreement with the measured results in cutting trials.
Authors: Kyung Hee Park, Dong Yoon Lee, Ki Hyeong Song, Seok Woo Lee
Abstract: An FE model can be usedfor better understanding the micro cutting process. To identify an edge wear effect, the cutting forces and contact stress on the cutting tool were measured as edge wear progress. On the other hand, a series of orthogonal cutting tests was also carried out forcomparisonwith FEM simulation results in termsof chip formation and cutting forces. A scanning electron microscope (SEM) was used to observe the tools and chips for the purpose of taking measurements. A Kistler dynamometer was also utilized for cutting forces measurement. The FEM micro cutting simulation showed good agreement with experimentalresults in terms of the cutting forces and chip formation. And it was observed in both FEM simulations and experiments that larger edge wear caused higher cutting forces.
Authors: Ai Qin Lin, Min Li Zheng, Yan Gu
Abstract: The present work aims at simulating three-dimensional milling operation of aluminum allo7451.Building a nose ring radius and edge radius tool model. Using finite element analysis software , conducted a three-dimensional simulation of milling process. Milling force, milling temperature, stress distribution and chip shape of milling process have been got. A milling force experiment was carried out under the same cutting conditions as the simulation, and a good agreement between the simulation result and the experimental result was achieved, and chip shape matched the practice well. The simulation shows that the three-dimensional finite element milling cutter model and the workpiece model can be used to correctly simulate precision milling process, optimizing the cutting parameters by analyzing variation of the cutting force, the temperature and equivalent stress.
Authors: Hassan Zamani, Jan Patrick Hermani, Bernhard Sonderegger, Christof Sommitsch
Abstract: During machining of hard materials, one approach to reduce tool wear is using a laser beam to preheat the material in front of the cutting zone. In this study, a new concept of laser-assisted milling with spindle and tool integrated laser beam guiding has been tested. The laser beam is located at the cutting edge and moving synchronously with the cutter. In experiment, a reduction in the resulting process cutting forces and tool wear has been observed in comparison to milling without laser. A three-dimensional finite element model in DEFORM 3D was developed to predict the cutting forces in the milling process with and without an additional laser heat source, based on a Johnson-Cook-type material constitutive model adapted for high strains and strain rates. Both in experiment and simulation, the deformation behavior of a Ti-6Al-4V workpiece has been investigated. The comparison of the resulting cutting forces showed very good agreement. Thus the new model has great potential to further optimize laser assisted machining processes.
Authors: Tao Wang, Li Jing Xie, Xi Bin Wang
Abstract: The aim of this paper is to compare the predicting ability of the orthogonal cutting models developed by three commonly used finite element softwares, namely commercial explicit dynamic code Abaqus/explicit, Thirdwave AdvantEdge and implicit finite element codes Deform 2D. In all proposed models, the chip formation was simulated through adaptive remeshing and plastic flow of work material around the round edge of the cutting tool. Therefore, there was no need for a chip separation criterion which made the physical process simulation more realistically. Predicted cutting, feed force and shear angle were compared with experimental results. In addition, the effect of friction coefficient on the chip morphology was investigated as well.
Authors: Yu Jun Cai, Chun Zheng Duan, Li Jie Sun
Abstract: Sculpture surface machining is a critical process commonly used in die/mold industries. Since there is a lack of scientific tools in practical process planning stages, feedrates for CNC machining are set individual constant values all along the toolpath. In this paper, an enhanced mathematical cutting force model is presented and is used for selecting varying and ‘appropriate’ feed values along the tool path in order to decrease the cycle time in sculpture surface machining. The model is tested under various machining conditions and proved to be effective.
Authors: Guo Hua Qin, S.Q. Xin, Dong Lu, Yi Ming Rong
Abstract: In the field of aeronautical and astronautical manufacturing, milling is a basic machining process by which a surface is generated by progressive chip removal. Therefore, this paper reports a complete procedure of the finite element model for the 3D oblique milling process using the commercial software package ABAQUS. Effect of various parameters on cutting forces is mainly discussed. The model correctly exhibits the observed transition from small to large force with increasing cutting speed and cutting depth.
Authors: Guang Ming Zheng, Jun Zhao, Xin Yu Song, Xiang Cheng
Abstract: A 3D finite element model (FEM) of metal cutting was constructed based on the thermal-mechanical coupling theory. The cutting process of Sialon ceramic tools turning Inconel 718 was simulated and experimented. The effect of cutting speed, feed rate and depth of cut on the cutting force was analyzed. According to the correlation characteristics between the data points, the fractal characteristics of cutting forces in the cutting process were also investigated. The results showed that the cutting speed had a great effect on the fractal dimension of cutting force. The simulation results were in good agreement with the experimental findings. It was concluded that the minimum fractal dimension of cutting force was obtained at v=230 m/min under these experiment conditions. The fractal analysis is a simple and powerful tool for quantifying the stability of cutting process. The finding of this research is valuable for future practical implementation.
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