Papers by Keyword: Oblique Cutting

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Authors: Jing Sheng, Li Ping Yao
Abstract: The finite element simulation of metal machining is a complex process. It is essential to develop a system to construct a model of simulation so as to obtain simulation data conveniently and rapidly. The paper detailed the parametric modeling. The key techniques of 3D modeling with MSC.Marc software and the parametric modeling procedure of metal oblique cutting process were presented in the paper. The modeling rule based on the procedure file was investigated. The interface of the system, designed using C++ Builder, could access data, which includes the geometrical angles and dimensions of a tool, the sizes of a workpiece, the relative position between the tool and the workpiece, their properties and cutting conditions, etc.. The procedure file, which is able to model in the MSC.Marc environment, was created by the program automatically. Calling the file, the system can finish the parametrical modeling of the finite element simulation. Then an example was given and the simulation model was also run. It was proved that the parametric modeling is an effective way for metal cutting simulation.
Authors: Nicolas Guillemot, Benoît Beaubier, Tarek Braham, Claire Lartigue, René Billardon
Abstract: The objective of this study is to predict the residual stresses induced by ball-end milling using an hybrid approach based on a numerical simulation where thermo-mechanical loads equivalent to the cutting process are applied directly on to the final surface of the workpiece without modelling the material removal. The applied loading is derived from the measurement of the maximum cutting forces and the measurement by IR camera of the temperature in the tertiary shear zone. The 2D simplified model proposed herein is derived from the analysis of oblique cutting with elementary cutting tools and makes it possible to take account of the normal rake and local helix angles as well as the lead angle of the tool. The feasibility of the approach is assessed by comparing experimental measurements and numerical predictions of the residual stresses induced by ball-end tool finishing milling of flat specimens made of a bainitic steel.
Authors: Xiao Dong Zhang, Ce Han, Ding Hua Zhang, Ming Luo
Abstract: A unified oblique cutting force model for flat end mills is developed. In this model, the cutting force is bridged among cutter geometry, material properties and cutting parameters. The cutter angles, material parameters and cutting parameters are the only inputs so that the model is applicable for different cutter-workpiece combinations and cutting parameters. The parameters in the model are solved by the geometric relations, applying Maximum Shear Stress Principle and Stabler’s chip flow rule. The material parameters are identified in a new method with orthogonal milling tests. The simulation results of the proposed model are in good agreement with experiments.
Authors: Wei Guo Wu, Gui Cheng Wang, Chun Gen Shen
Abstract: In this work, the prediction and analysis of cutting forces in helical ball-end milling operations is presented. The cutting forces model for helical end-mills is based on the oblique cutting theory and the geometric relations of the ball-end milling process. The helical flutes are divided into small differential oblique cutting edge segments. According to the transformation relationship between the local and global coordinate system of the cutter, the differential cutting force of cutting element is obtained by two coordinate conversions from the orthogonal cutting force. The total cutting force of helical ball-end milling is the sum of the cutting force in whole cutting field of the miller. As a result, the predicted cutting forces show an agreement with the values from the cutting experiments.
Authors: Wei Guo Wu, Gui Cheng Wang, Chun Gen Shen
Abstract: In this work, the prediction and analysis of cutting forces in precision turning operations is presented. The model of cutting forces is based on the oblique cutting force model which was rebuilt by two coordinate conversions from the orthogonal cutting model. Then the cutting field in precision turning was divided into two fields which are characterized as curve change and linear change on cutter edge and they were modeled respectively. Cutting field of cutter nose was modeled by differential method and its cutting force distribution is predicted by the proposed method. The predicted results for the cutting forces are in agreement with the experimental results under a variety of operation variables, including changes in the depths of cut and in the feedrate.
Authors: Riaz Muhammad, Naseer Ahmed, Murat Demiral, Anish Roy, Vadim V. Silberschmidt
Abstract: Industrial applications of titanium alloys especially in aerospace, marine and offshore industries have grown significantly over the years primarily due to their high strength, light weight as well as good fatigue and corrosion-resistance properties. The machinability of these difficult-to-cut metallic materials with conventional turning (CT) techniques has seen a limited improvement over the years. Ultrasonically-assisted turnning (UAT) is an advanced machining process, which has shown to have specific advantages, especially in the machining of high-strength alloys. In this study a three-dimensional finite element model of ultrasonically-assisted oblique cutting of a Ti-based super-alloy is developed. The nonlinear temperature-sensitive material behaviour is incorporated in our numerical simulations based on results obtained with split-Hopkinson pressure bar tests. Various contact conditions are considered at the tool tip-workpiece interface to get an in-depth understanding of the mechanism influencing cutting parameters. The simulation results obtained are compared for both CT and UAT conditions to elucidate main deformation mechanisms responsible for the observed changes in the material’s responses to cutting techniques.
Authors: A.V. Filippov
Abstract: The article presents a method for constructing a three-dimensional model of the equivalent wedge oblique cutting edge. This technique allows you to visually assess the complexity of changing the geometry of the tool and can be used in the design of cutting edge with a curved wedge. To construct a model, the equation of a space curve of cutting edge working part was derived. The article also shows the position of the tool-in-hand and the setting system in the developed model.
Authors: Osamu Horiuchi, Riyo Itabashi, Yoshikazu Mitoma, Hideo Shibutani, Hirofumi Suzuki
Authors: Ya Wang, Song Chen, Min Wang
Abstract: In recently years, researches about round-hole broaching mainly focus on broach macro environment and industry structure. However, researchers study little from technical level. We aim at simplifying broaching process of worm gear round broach into rectangular and oblique cutting process. In the same conditions, we make use of finite element analysis software for stress analysis of two kinds of cutting mode broach, to provide a certain theoretical basis for using tool reasonably and tool parameters optimization design in the production.
Authors: Yu Wang, Peng Wang, Hong Min Pen, Yu Fu Li, Xian Li Liu
Abstract: Experiment of hard cutting GCr15 with PCBN cutting tools, the influence of tool’s inclination angle and cutting parameters (cutting speed and feed speed) on cutting forces and cutting temperature are studied. A three-dimensional finite elements model using the commercial software Deform 3D 5.03 is developed. The friction between the tool and the chip is assumed to follow a modified Coulomb friction law and the adaptive remeshing technique is using for the formation of chip. The workpiece material property is a function of temperature, strain, and strain rate in the primary and secondary shear zones. Finite element method is used to simulate three-dimensional precision cutting, including orthogonal cutting and oblique cutting. The cutting forces and back forces are slightly changed by tool’s inclination angle. However, in high cutting speed, the cutting force decrease as the tool’s inclination angle increase, while the cutting temperature increase as the tool’s inclination angle increase. The simulation results are compared with experimentally measured data and found to be in good agreement to some extent.
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