Papers by Keyword: Metal Cutting

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Authors: Subrata Chatterjee, Srinivasan Chandrashekhar
Authors: Xue Feng Bi, Gautier List, G. Sutter, A. Molinari, Yong Xian Liu
Abstract: Chip velocity is a crucial parameter in metal cutting. The continuous variation of chip velocity in primary shear zone can not be obtained from conventional shear plane model. Therefore a general streamline model was used to investigate the distribution of chip velocity field in metal cutting. This paper also verified the continuity of plastic flow in metal cutting by tracing the variation of particle area. The velocity of chip material was calculated from the mathematical expression of streamline model. The velocity results were compared with conventional shear plane model.
Authors: Yue Feng Yuan, Wu Yi Chen, Dong Liu
Abstract: A new simple methodology to determine the flow stress of material is presented and Johnson–Cook (JC) constitutive model of titanium alloy Ti6Al4V is obtained via this approach. The JC model is verified by comparison between simulations and experiments. The results show that the model is suitable for cutting simulation. This simple method can be used to determine conveniently JC model not only in the scientific research but also in the workshop production.
Authors: Hans Kurt Tönshoff, Berend Denkena, H.H. Apmann
Authors: Jian Bing Cheng, Si Qin Pang, Xi Bin Wang, Qi Xun Yu
Abstract: Tool life tests of continuous cutting superalloy GH2132 were carried out by WC/Co cemented carbide cutting inserts of different grain size and cobalt content, and flank surface wear morphology of the cutting inserts were observed by ZEISS continuous zoom stereo microscope and microphotograph system. The results show that grain size and cobalt content strongly influence the cutting tool life and tool wear, grain refinement and proper cobalt content are help to improve the tool life and the wear resistance of WC/Co cemented carbide. The wear mechanisms of different grain size and cobalt content of ultrafine cemented carbide tools were adhesion and notch, among them, adhesive was the main wear mechanism at higher cutting speeds.
Authors: Wen Jun Deng, Yong Tang, Wei Xia, Zhen Ping Wan
Abstract: A coupled thermal-mechanical model of plane-strain orthogonal metal cutting with continuous chip formation is developed to investigate the residual stresses in the finished workpiece. Deformation of the workpiece material is treated as elastic-viscoplastic with isotropic strain hardening, and the numerical solution accounts for coupling between plastic deformation and the temperature field, including treatment of temperature-dependent material properties. Automatic continuous remeshing and adaptive meshing technique are employed to achieve chip separation at the tool tip region and a satisfactory solution. The finite element model is well validated by comparing values of the predicted cutting forces and residual stresses with experimental results. Based on the established finite element model, the effect of rounded cutting edge radius on residual stress distribution is analyzed. The results show that altered cutting edge radius clearly produced significant changes in residual stresses. The maximum tensile residual stress and its penetration depth decrease as the cutting edge radius increases.
Authors: Francisco Valdenor Pereira da Silva, José Paulo Vogel, Rodinei Medeiros Gomes, Tadeu Antonio de Azevedo Melo, Anna Carla Araujo, Silvio Romero de Barros
Abstract: This work studies the effect of heat treatment and cutting velocities on machining cutting forces in turning of a Cu-11.8%Al-0.55%Be shape memory alloys. The heat treatment was performed to obtain samples with austenite and martensite microstructures. Cutting force was investigated using a 3-component dynamometer in several revolutions and data were analyzed using statistic tools. It was found that the resultant forces were higher in quenched alloy due to the presence of Shape Memory Effect. Chip formation occurred in a shorter time in the sample without the Shape Memory Effect.
Authors: X.L. Zhao, Yong Tang, Wen Jun Deng, F.Y. Zhang
Abstract: A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.
Authors: J.C. Outeiro, Domenico Umbrello, Rachid M'Saoubi
Abstract: The reliability of a mechanical component depends to a large extent on the physical state of its surface layers. This state includes the distribution of residual stresses induced by machining. Residual stresses in the machined surface and subsurface are affected by the cutting tool, work material, contact conditions on the interfaces, cutting regime parameters (cutting speed, feed and depth of cut), but also depends on the cutting procedure. In this paper, the effects of cutting sequence on the residual stress distribution in the machined surface of AISI 316L steel are experimentally and numerically investigated. In the former case, the X-ray diffraction technique is applied, while in the latter an elastic-viscoplastic FEM formulation is implemented. The results show that sequential cut tends to increase superficial residual stresses. A greater variation in residual stresses is observed between the first and the second cut. Moreover, an increase in the thickness of the tensile layer is also observed with the number of cuts, this difference also being greater between the first and the second cut. Based on these results, the residual stress distribution on the affected machined layers can be controlled by optimizing the cutting sequence.
Authors: A.V. Proskokov, A.V. Filippov, V.V. Gorbatenko
Abstract: The paper considers the intensity degree of a plastic shear deformation ei when cutting, the results of experimental studies that determine a travel trajectory of a cutting material layer through a plastic deformation zone in a chipping area and comparative analysis of deformation conditions of a sample material machined by various tool rake angles (γ=0o and γ=15o).
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