A machining theory for predicting chip geometry, cutting forces etc. from work material properties and cutting conditions

1980 ◽  
Vol 371 (1747) ◽  
pp. 569-587 ◽  
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Carbon Steels ◽  
Cutting Conditions ◽  
Strain Rates ◽  
Compression Tests ◽  
Rate Dependent ◽  
Work Material ◽  
Flow Stress Data

An approximate machining theory is described in which account is taken of the temperature and strain-rate dependent properties of the work material. A feature of the theory is that the strain rates in the zones of intense plastic deformation in which the chip is formed and along the tool/ chip interface are determined as part of the solution. The theory is applied to make predictions for two plain carbon steels and a range of cutting conditions by using flow stress data obtained from high speed compression tests and excellent agreement is shown, for example, between predicted and experimental cutting forces. The values of tool/chip interface plastic zone thickness predicted by assuming a minimum work criterion are shown to agree well with experimental values, both experiment and theory indicating a marked decrease in thickness with increase in cutting speed. It is also shown how the temperatures and strain rates in this zone can be used to determine the conditions that cause a built-up edge to be formed on the cutting tool and good agreement is again shown with experimental results.

scholarly journals Mechanics of Machining With Chamfered Tools

1999 ◽  
Vol 122 (4) ◽  
pp. 650-659 ◽  
Author(s):  
H. Ren ◽  
Y. Altintas
Keyword(s):  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Minimum Energy ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Analytic Model

Chamfered cutting tools are used in high speed machining of hardened steels due to their wedge strength. An analytic model is proposed to investigate the influence of chamfer angle and cutting conditions on the cutting forces and temperature. The model is based on the tool geometry, cutting conditions, steady state temperature in the shear and chip-rake face contact zones, strain, strain rate, and the corresponding flow stress of the work material. With the aid of a slip line field model, the cutting and friction energy in the primary, secondary and chamfer zones are evaluated. By applying the minimum energy principle to total energy, the shear angle in the primary deformation zone is estimated. The corresponding shear strain, strain rate and flow stresses are identified. The model leads to the prediction of cutting forces and temperature produced in three deformation zones. The model is experimentally verified by high-speed orthogonal cutting tests applied to P20 mold steel using ISO S10 carbide and CBN cutting tools. It is shown that the analytic model is quite useful in selecting optimal chamfer angle and cutting speed which gives the minimum tool wear and relatively lower cutting forces. [S1087-1357(00)00204-5]

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Investigation of the axial compressive behavior of Kevlar fibers using the dynamic loop test

2019 ◽  
Vol 89 (18) ◽  
pp. 3825-3838
Author(s):  
Ahmad Abuobaid ◽  
Raja Ganesh ◽  
John W Gillespie
Keyword(s):  
Strain Rate ◽  
High Speed ◽  
Failure Strain ◽  
Kink Band ◽  
Test Method ◽  
Strain Rates ◽  
Compressive Failure ◽  
Band Formation ◽  
Rate Dependent ◽  
Strain And Strain Rate

A dynamic loop test method for measuring strain rate-dependent fiber properties was developed. During dynamic loop testing, the fiber ends are accelerated at constant levels of 20.8, 50 and 343 m/s2. The test method is used to study Kevlar® KM2-600, which fails in axial compression due to kink band formation. The compressive failure strain and strain rate at the onset of kink band formation is calculated from the critical loop diameter ( D C), which is monitored throughout the test using a high-speed camera. The results showed that compressive failure strain increases with strain rates from quasi-static to a maximum strain rate of 116 s−1 by a factor of ∼3. Kink angles (φ) and kink band spacing ( D S) were 60 ° ± 2 ° and 16 ± 3 μm, respectively, over the strain rates tested. Rate-dependent mechanisms of compressive failure by kink band formation were discussed.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Studies on Cutting Forces of High Volume Fraction SiCp/Al Composites with Ultrasonic Vibration High Speed Milling

2011 ◽  
Vol 295-297 ◽  
pp. 785-788 ◽  
Author(s):  
Dao Hui Xiang ◽  
Guang Xi Yue ◽  
Xin Tao Zhi ◽  
Hai Tao Liu ◽  
Bo Zhao
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
Matrix Composites ◽  
Machining Performance ◽  
High Speed Milling ◽  
Hard Cutting

The orthogonal method was used for analyzing the machining performance of high volume fraction SiCp/Al metal matrix composites (SiCp/Al MMCs) during high speed milling and ultrasonic high speed milling in this paper. The influence of cutting speed, feed rate and cutting depth on 3-directional forces were investigated. The results show that the cutting forces are decreased due to the cutting mechanism of SiCp/Al MMCs is changed from brittle cutting to ductile cutting during ultrasonic high speed milling. In addition, the chips exist in forms of C-type chips because of increasing rake angles. Ultrasonic high-speed milling is a more highly effective hard cutting way compared with high speed milling.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Influence of Work-Hardening on Wear Resistance of Machined Surface of Aviation Aluminum Alloy

2013 ◽  
Vol 589-590 ◽  
pp. 117-121 ◽  
Author(s):  
Xiu Li Fu ◽  
Zeng Hui An ◽  
Yang Qiao ◽  
Xiu Hua Men
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Micro Hardness ◽  
Machined Surface ◽  
And Performance

Work-hardening of machined surface plays an important role in the evaluation of surface quality and performance of wear resistance in the process of machining components. In this study work-hardening of machined surface during milling 7050-T7451 aluminum alloy is investigated using micro-hardness experiments under different cutting conditions. Moreover, the wear resistance of machined surface including wear quantity and friction coefficient are obtained and studied by means of high speed ring-block friction-wear tester. The work-hardening and wear resistance are particularly sensitive to cutting speed. Friction coefficient has marked drop trends and the tendency of wear quantity is ascend in first and descend at last as work-hardening increases. The comparison of wear resistance under different cutting conditions shows that the wear resistance of machined surface can be directly affected by work-hardening and machined surface obtained by high speed milling with higher micro-hardness have more superior in wear resistance performance.

A Study of Cutting Forces in High-Speed Dry Milling of Inconel 718

2012 ◽  
Vol 500 ◽  
pp. 105-110 ◽  
Author(s):  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Yield ◽  
Dry Milling ◽  
Machining Processes ◽  
Dry Cutting ◽  
High Tendency ◽  
Coated Carbide

nconel 718 is one of the most commercially important superalloys but with very poor machinability. It has a very high yield stress and a high tendency to adhesion and work-hardening. A recent trend of improving the machining processes of difficult-to-cut materials is to move towards dry cutting operations. This paper presents an experimental study of the cutting forces in high speed dry milling of Inconel 718 using a milling cutter with coated carbide inserts. It is found that the peak cutting forces increase with an increase in chip load in a nonlinear way, but cutting speed does not show a significant influence on the cutting force for the range of cutting speeds tested in this study.

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