The Influence Of Cutting Tool Rake Angle On Cutting Forces When Machining Aluminium Alloys(Advanced machining technology)

2005 ◽  
Vol 2005.1 (0) ◽  
pp. 173-176
Author(s):  
Sekmen Mustafa ◽  
Gunay Mustafa ◽  
Ibrahim Ciftci ◽  
Ihsan Korkut ◽  
Ulvi SEKER
Keyword(s):  
Cutting Forces ◽  
Aluminium Alloys ◽  
Cutting Tool ◽  
Rake Angle ◽  
Advanced Machining

Measurement and analysis of cutting forces on single point cutting tool in turning of MS bar with dry condition and rust-X cutting fluid

2016 ◽  
Vol 7 (3) ◽  
pp. 359-369 ◽  
Author(s):  
Pradeep Kumar Patil ◽  
A I Khandwawala
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Single Point ◽  
Rake Angle ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Experimental Setup ◽  
Rake Face ◽  
Content Type ◽  
Normal Forces

Purpose – The purpose of this paper is to measure the effect of rake angle on cutting forces on the rake face of single point cutting tool with two cutting conditions. The experimental setup has been developed to measure the cutting forces. The study aims to put forward the optimum cutting condition, which improves the product quality, surface finish, productivity and tool life. Design/methodology/approach – The load cell-based tool dynamometer has been developed to measure the cutting forces. The experiments have performed on the mild steel bar of hardness 60 BHN. The friction and the normal forces have measured in dry cutting condition and with rust-X cutting fluids. The cutting forces for these two cutting conditions have calculated with constant depth of cut, speed and feed with different rake angles in the range of degrees 6, 7, 8, 9, 10, 11, 12, 15 and 20. Findings – The experimental observations shows the variations of friction and normal forces with different cutting conditions and parameters. It shows the friction force on rake face increase and the normal force on the rake face decreases with increase the rake angle. Research limitations/implications – The observations has done only for mild steel of hardness 60 BHN. It can also be perform on different materials and for different cutting conditions. Practical implications – The experimental setup developed in this research can be used in the manufacturing industry. It can help to decide and maintain the optimum cutting conditions. Originality/value – The observations have been made on an experimental setup, which fulfills the actual working/cutting conditions as per the use in industries.

Finite Element Study of Ultrasonic Elliptical Vibration Turning of Ti6Al4V

2014 ◽  
Vol 494-495 ◽  
pp. 383-386 ◽  
Author(s):  
Dong Lu ◽  
Li Gang Cai ◽  
Qiang Cheng
Keyword(s):  
Finite Element ◽  
Vibration Frequency ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Finite Element Models ◽  
Elliptical Vibration ◽  
Advanced Machining ◽  
Ultrasonic Elliptical Vibration

Ultrasonic elliptical vibration turning (UEVT) is an advanced machining technique for difficult-to-cut materials, in which with frequency in excess of 20 KHz is superimposed on the cutting tools movement. In order to analyze the effect of vibration frequency on cutting forces and cutting temperature, finite element models of ultrasonic elliptical vibration turning were developed. The cutting forces and the distribution of the temperature on workpiece and cutting tool were predicted. It is observed that the cutting forces and cutting temperature decrease with the increase of the vibration frequency.

Influence of Friction and Rake Angle on the Formation of Discontinuous Rock Fragments During Rock Cutting

2010 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell ◽  
C. Fred Higgs
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Material ◽  
Fragmentation Process ◽  
Rock Fragment ◽  
Explicit Finite Element ◽  
Rock Fragments

Tribological properties during rock cutting under extremely high pressure and high temperature (HPHT) conditions are important in deep mining and drilling operations. In the present investigation, a rock fragmentation process is simulated during mechanical cutting of rock using an explicit finite element code, LS-DYNA. In the simulations, a rigid steel cutting tool of different rake angles was moved at different velocities against a stationary rock material. Rock material properties have been incorporated using an advanced damage constitute material model. In addition, the friction factors at the cutting tool–rock interface were varied in the contact model. The variation of cutting forces, stresses and rock fragment morphology have been investigated. Overall, the results indicate that the explicit finite element model is a powerful tool for simulating rock cutting and the fragmentation process. More specifically, the separation of rock fragments from the rock slab was accurately predicted using the numerical model. The rake angle was found to have significant influence on the fragment morphology during rock cutting. Moreover, the cutting forces and the discontinuous fragmentation process were strongly influenced by the friction and cutting velocity.

scholarly journals 3D Finite Element Analysis of Cutting Forces in the Process of Machining Rectangular Microchannels

2014 ◽  
Vol 8 (1) ◽  
pp. 726-730
Author(s):  
Zhanshu He ◽  
Dalei Li ◽  
Lianduo Cao ◽  
Xuefei Yang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
3D Fem ◽  
Element Analysis ◽  
Rectangular Microchannels ◽  
Side Face

In the process of machining rectangular microchannels, severe friction occurs between the chip and the side face of the machined microchannel. The cutting forces have great effect on the miniature cutting tool. Thus, 3D FEM is adopted to study the cutting forces. The influences of the depth of the machined microchannel t, the cutting depth ac, the cutting width aw , the rake angle ○o and the cutting speed ν on the cutting forces are investigated. Results show that the main cutting force Fz and the thrust force Fy increase with the increase of t, ac and aw and have no obvious change with ν. Moreover, Fz decreases and Fy increases as γ○ increases.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Discrete Element Simulation of the Stress Wave in High Speed Milling

2017 ◽  
Author(s):  
Yifei Jiang ◽  
Jun Zhang ◽  
Yong He ◽  
Hongguang Liu ◽  
Afaque Rafique Memon ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Discrete Element ◽  
Rake Angle ◽  
Stress Waves ◽  
High Speed Milling ◽  
Element Simulation ◽  
Chip Size ◽  
Distribution Of Stress

As cutting tool penetrates into workpiece, stress waves is induced and propagates in the workpiece. This paper aims to propose a two-dimensional discrete element method to analyze the stress waves effects during high speed milling. The dependence of the stress waves propagation characteristics on rake angle and cutting speed was studied. The simulation results show that the energy distribution of stress waves is more concentrated near the tool tip as the rake angle or the cutting speed increases. In addition, the density of initial cracks in the workpiece near the cutting tool increases when the cutting speed is higher. The high speed milling experiments indicate that the chip size decreases as the cutting speed increases, which is just qualitatively consistent with the simulation.

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

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