Papers by Keyword: Metal Cutting

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Authors: Yue Feng Yuan, Wu Yi Chen
Abstract: It is necessary for cutting simulation to determine the friction model at the tool-chip interface suitable for metal cutting process. Cutting force experiments in orthogonal turning titanium alloy TI6AL4V are carried out with cement carbide tool KW10. The Coulomb frictions at the tool-chip interface are calculated based on measured cutting force, and the friction model is regressed, where cutting speed and feed rate are presented.
Authors: Maria José Marques, J.C. Outeiro, A. Morão Dias, Rachid M'Saoubi, Hariharan Chandrasekaran
Abstract: The quality of a mechanical component such as its geometrical accuracy stability and fatigue life are significantly affected by the surface integrity generated by machining process. Residual stresses are a major part of the mechanical state of a machined layer and they can be beneficial or detrimental depending of their nature and magnitude. This study concerns phase analysis and residual stress profile characterization by X-ray diffraction (XRD) technique and microhardness profile of AISI H13 ESR mould steel, milled using carbide and CBN tools. Analysis of the cross-section of the AISI H13 ESR samples, milled using both tools, reveal a martensitic microstructure, with a very thin layer heavily deformed due to the machining process. However, no phase transformation was detected by XRD. Concerning the residual stresses, the results show that they are predominantly compressive at the samples surface. However, depending of the cutting tools, the in-depth residual stresses profiles present different evolutions. This difference in the in-depth residual stresses profiles between the two kind of cutting tools is attributed to the different cutting tool parameters, including the tool geometry.
Authors: Jian Bing Cheng, Si Qin Pang, Xi Bin Wang, Xi Bin Wang, Chen Guang Lin
Abstract: This work contributes to a better understanding of wear mechanisms of ultrafine cemented carbide cutting tools used in turning operation of superalloy and high strength steels at high cutting speeds. The main objective of this work is to verify the influence of grain size and the cobalt content of ultrafine cemented carbide tools on tool life and tool wear mechanism. The main conclusions are that grain size and the cobalt content of ultrafine cemented carbide tools strongly influence tool life and tool wear involve different mechanisms. The wear mechanisms of different grain size and the cobalt content of ultrafine cemented carbide tools observed on the rake face at these conditions were adhesion and notch, at the end of tool life, adhesion was the main wear mechanism at higher cutting speeds.
Authors: Viktors Gutakovskis, Eriks Gerins, Janis Rudzitis, Artis Kromanis
Abstract: From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.
Authors: Shi Gang Wang, Yue Qiang Yu, Fu Sheng Gao, Xi Bing Li
Abstract: Using the finite element analysis software ABAQUS, simulation experiments on physical nonlinearity, geometric nonlinear, nonlinear finite element, elastic-plastic in the cutting process are conducted, which realize the separation of chips and working piece combined with material failure criterion, shear failure, adaptive grid technique in ABAQUS. Meanwhile, the stress field, strain and temperature field and cutting force in the cutting simulation are obtained consistent with cutting theory.
Authors: Xiao Hang Wan, Zhao Wei Dong, Shu Jun Li, Sheng Yong Liu
Abstract: Adopted the theory of elastic-plastic deformation, used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the adaptive meshing criteria and simulates a typical work-piece chip breaking process. This paper simulates different tool orthogonal rakes how affect the cutting process, which is very significant in engineering. This paper supplies the theory foundation of optimizing the technical parameters and deeply studying the cutting mechanism.
Authors: H. Miguélez, C. Santiuste, José Díaz, X. Soldani, J.L. Cantero
Abstract: Despite of the efforts focused on the improvement of simulation of machining processes, this problem remains still open. In the case of metal cutting, 2D (two dimensional) modeling has been extensively used for decades in the prediction of difficult to measure variables in metal cutting. Although more complex 3D (three dimensional) approaches have been carried out they have still high computational cost. On the other hand long fiber reinforced composites are extensively used in industry; however the numerical modeling of composite cutting is still poorly developed, and mainly focused on 2D approach. Two dimensional approaches imply some simplifying hypotheses and limitations those could influence the results obtained from the analysis. This paper focuses on phenomena involved during cutting of metals and composite those should modeled using three dimensional approaches.
Authors: Eric Segebade, Johannes Schneider, Volker Schulze
Abstract: In metal cutting, a severe thermo-mechanical load collective determines the friction and wear behavior at the tool-chip interface. The inaccessibility of this interface complicates studies and thus the understanding of tribological effects in metal cutting. During a tool’s lifetime, local friction conditions change drastically as coatings and tool geometry wear down. This paper shall provide a comprehensive overview of current methods to understand and describe friction conditions in metal cutting and how cutting induced surface layer states may influence the friction and wear behavior of the finished workpiece.
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