Papers by Keyword: Metal Cutting

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Authors: A.V. Filippov, V.V. Gorbatenko
Abstract: The article considers experimental studies of plastic deformation in the area of chip formation when cutting copper M1. According to the results of the research the value of shear deformation was calculated. The change of a rake angle tool γ leads to the change in the process of plastic deformation in the area of chip formation. It was found out that the maximum degree of shear deformation takes place in the contact area of tool tip and deformable sample.
Authors: Xin Li Tian, Zhao Li, Xiu Jian Tang, Fang Guo, Ai Bing Yu
Abstract: Tool edge radius has obvious influences on micro-cutting process. It considers the ratio of the cutting edge radius and the uncut chip thickness as the relative tool sharpness (RST). FEM simulations of orthogonal cutting processes were studied with dynamics explicit ALE method. AISI 1045 steel was chosen for workpiece, and cemented carbide was chosen for cutting tool. Sixteen cutting edges with different RTS values were chosen for analysis. Cutting forces and temperature distributions were calculated for carbide cutting tools with these RTS values. Cutting edge with a small RTS obtains large cutting forces. Ploughing force tend to sharply increase when the RTS of the cutting edge is small. Cutting edge with a reasonable RTS reduces the heat generation and presents reasonable temperature distributions, which is beneficial to cutting life. The force and temperature distributions demonstrate that there is a reasonable RTS range for the cutting edge.
Authors: J.C. Outeiro, A. Morão Dias
Abstract: Machining residual stresses are considered as part of surface integrity and a consequence of the machining process. Theses stresses are closely correlated with the corresponding process parameters, including the work material properties. As it is well known, not only the mechanical but also the physical properties of the work materials have great influence on machining residual stress. This was demonstrated in the present work through studying the residual stress and work hardening induced by the turning of AISI 316L and AISI 1045 steels. The residual stresses were determined at the workpiece surface and in-depth using the X-ray diffraction technique. To understand the influence of the work material properties on the residual stress and work hardening distributions, the mechanical and thermal phenomena occurring during the cutting process were studied, using a t developed experimental procedure. The experimental setup included a piezoelectric dynamometer to determine the cutting forces, and thermal imaging equipment developed to assess the temperature distribution in the deformation zone in turning. The results showed that the cutting forces and temperatures in the machining of 316L steel are much higher than those in the machining of 1045 steel. Thus, machining 316L steel, when compared to 1045 steel, results in higher superficial residual stresses and stronger in-depth residual stress gradients, higher superficial work-hardening and greater thickness of the work hardened layer.
Authors: Pedro A. R. Rosa, Valentino A. M. Cristino, Carlos M.A. Silva, Paulo A. F. Martins
Abstract: This paper is focused on the fundamentals of metal cutting and is aimed at enabling the readers to recognize the validity of test calibration procedures, to identify the possible sources of modelling errors and to understand the routes to improve the overall accuracy and reliability of physical, tribological and mechanical input data for the numerical simulation of metal cutting processes. Innovative testing equipments, experimental methodologies and numerical procedures developed by the authors give support to the presentation.
Authors: Vladas Vekteris
Abstract: Lubrication and cooling of a high speed grinding process in the grinding machine as in a mechatronic system using technological liquids are analyzed in this paper. It is shown that in the case of high grinding speed, technological liquids undergo an aeration process and due to this their physical properties change. Reynolds equation, which estimates the aeration liquid, is derived. It is shown, that the application of such an equation is proper only in the finishing of grinding. Experimental research is also presented in the paper, which shows the influence of technological liquids to the temperature field of the grinding machine and to its automatic control.
Authors: Yong Yang, Yu Ling Wang, Chang He Li
Abstract: A three-dimensional finite element model of helix double-edge cutting is developed to study the ending milling process of titanium alloy Ti6Al4V. Several mechanics models of milling process, such as material constitutive model, friction model and heat transfer model, are implemented to improve finite element simulating accuracy. A milling force experiment is carried out, and a good agreement between simulation and experimental value is achieved, which proved that the finite element model presented in this paper is correct. Using this finite element model, chip formation and cutting temperature are simulated and analyzed. This work will be a base for process parameter optimization, tool’s optimization selection and design during high speed milling of difficult-to-cut titanium alloy.
Authors: Gui Cheng Wang, Chun Yan Zhang
Authors: Kuldip Singh Sangwan, Girish Kant, Aditya Deshpande, Pankaj Sharma
Abstract: This paper focuses on finite element modeling of orthogonal cutting process of AISI 1045 steel using Modified Johnson Cook (MJC) as constitutive material flow model under various machining parameters. Finite element solutions of cutting forces, effective stresses and temperature are obtained for a wide range of cutting speeds and feeds. The effect of feed and cutting speed on cutting forces, effective stresses and temperature has been studied over a wide range of values. Percentage variation of each is also studied to predict co-relation with the different machining parameters.
Authors: You Xin Luo
Abstract: Based on grey system theory, a novel kind of non-equidistant optimum grey model GM(1,1) with optimizing modified the nth component taken as initial value of response function of grey differential equation and reconstructing the background value function to obtain the approximately expressions of parameters of the background value function was proposed, the method of precision inspection was introduced. The example was given. The method can be used for model establishing on equal interval, as well as on non-interval. Moreover, GM(1,1) model’s fitting precision and prediction is advanced and the scope of application is enlarged. The model is simple and practical, and has a generalizing value in metal cutting data process.
Authors: Song Jie Yu, Di Di Wang, Xin Chen
Abstract: Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.
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