Formation and Simulation of Two-Side Burr in Orthogonal Cutting

2008 ◽  
Vol 53-54 ◽  
pp. 77-82 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Yun Ming Zhu ◽  
Qin Xi Shen
Keyword(s):  
Formation Process ◽  
Orthogonal Cutting ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Burr Size ◽  
Edge Quality ◽  
And Performance

The two-side burr is one of the important factors that influence the edge quality and performance of precision parts. The two side-direction burr formation process is simulated with DeformTH3D. The mechanism of two-side burr formation is analyzed in terms of the results of the simulation. Enlarging the tool orthogonal rake and minimizing the depth of cut can reduce the burr size.

Formation and Simulation of Cutting-Direction Burr in Orthogonal Cutting

2007 ◽  
Vol 24-25 ◽  
pp. 249-254 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Hong Jie Pei ◽  
Qin Feng Li ◽  
Yun Ming Zhu
Keyword(s):  
Shear Zone ◽  
Formation Process ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Burr Formation ◽  
Size And Shape ◽  
Study Results ◽  
Edge Quality ◽  
And Performance ◽  
Cutting Direction

The cutting-direction burr is one of the important factors that influence the edge quality and performance of precision parts. The cutting-direction burr formation process is simulated with DeformTH3D. The mechanism of cutting-direction burr formation is analyzed in terms of the results of the simulation. The negative shear zone and initiation negative shear angle are discussed too. Study results show that the deformation of CDE is an important factor affect the cutting direction burrs’ size and shape.

Research on the Modeling and Experimenting of Burr Formation Process in Double-Edged Micro-Plat End Milling Operation

2013 ◽  
Vol 770 ◽  
pp. 248-252 ◽  
Author(s):  
Ni Chen ◽  
Ming Jun Chen ◽  
Hai Bo Ni ◽  
Ning He ◽  
Zhan Qiang Liu
Keyword(s):  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Generation Process ◽  
Burr Size ◽  
Milling Operation ◽  
Exit Burr

Burrs generated in micro-milling operation have a significant impact on the surface quality and operational performance of the finished microstructures. In order to gain a better recognition of burr generation process, 3-dimensional double-edged micro-flat end milling operation FEM models on Ti6Al4V have been established. Burrs occurred in simulation can be classified into three types: entrance burr, exit burr, top burr. Their formation processes and causes are well investigated and analyzed, moreover, a series of experiments are conducted to validate the burr morphologies which are received in simulation. At last, the effect of cutting parameters on top burr size is studied through orthogonal experiment on Ti6Al4V, it can be concluded that the axial depth of cut has the greatest effect on top burr size, and the effect of spindle speed on top burr size is the least.

Formation of Cutting Direction Burr/Fracture in Orthogonal Cutting

2012 ◽  
Vol 426 ◽  
pp. 73-76 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Y.M Zhu ◽  
Q.X Shen
Keyword(s):  
Mechanical Properties ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Material Failure ◽  
Forming Process ◽  
Fracture Formation ◽  
Edge Quality ◽  
Simulation Results ◽  
And Performance ◽  
Cutting Direction

Cutting direction burr/fracture is one of the important factors that influence the edge quality and performance of precision parts. A finite element model based on material failure mode is developed in this study to simulate the burr /fracture forming process. According to workpiece materials deformation and mechanical properties from the simulation results, the cutting direction burr/fracture formation process is analyzed. The cutting direction burr forms when there is a crack in the area near the tool tip and grow along the principal shear zone, the cutting direction fracture forms as the crack grow along negative zone.

Analysis of Burr Formation Mechanism in Orthogonal Cutting

1999 ◽  
Vol 121 (1) ◽  
pp. 1-7 ◽  
Author(s):  
M. Hashimura ◽  
Y. P. Chang ◽  
David Dornfeld
Keyword(s):  
Conceptual Understanding ◽  
Formation Process ◽  
Orthogonal Cutting ◽  
Fem Analysis ◽  
Optical Microscope ◽  
Burr Formation ◽  
Micro Machining ◽  
Experimental Conditions ◽  
Tool Edge ◽  
Al 2024

To prevent problems caused by burrs in machining, reduction and control of burr size is desirable. This paper presents a basic framework for and conceptual understanding of the burr formation process based upon the material properties of the workpiece. In order to verify this framework and explain the basic phenomena in the burr formation process, the deformation at the edge of the workpiece was analyzed using a finite element method (FEM). Micro-machining tests under an optical microscope and a scanning electron microscope using Al-2024-O material were also done to observe the burr formation process. The feed rate and tool edge radius were varied and the resulting burr formation observed. FEM analysis of burr formation in the 2024 material and observation of the deformation at the workpiece edge in the micro-machining tests verified the proposed conceptual understanding of the burr formation process. For the experimental conditions examined, all of the burrs in Al-2024-O were “negative” burrs, that is, edge breakout. As the feed was increased two effects were observed. One effect was an increase in the resulting burr thickness. Another effect, which was observed during the burr initiation stage while machining with a sharp tool, was an increase in both the distance and depth of the initial pivoting point of the burr from the tool edge.

Milling Burr Size Estimation Using Acoustic Emission and Cutting Forces

2011 ◽  
Author(s):  
Seyed Ali Niknam ◽  
Azziz Tiabi ◽  
Imed Zaghbani ◽  
Rene Kamguem ◽  
Victor Songmene
Keyword(s):  
Acoustic Emission ◽  
Cutting Forces ◽  
Estimation Method ◽  
Cutting Speed ◽  
Measurement Methods ◽  
Estimation Methods ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Size Estimation ◽  
Burr Size

Burr formation is one of the main concerns usually faced by machining industries. Its presence leads to additional part edge finishing operations that are costly and time consuming. Burrs must be removed as they are source of dimensional errors, jamming and misalignment during assembly. In many cases burrs may injure workers during handling of machined part. Due to burr effect on machined part quality, manufacturing costs and productivity, more focus has been given to burr measurement/estimation methods. Large number of burr measurement methods has been introduced according to various criteria. The selection of appropriate burr size estimation method depends on number of factors such as desired level of quality and requested measuring accuracy. Traditional burr measurement methods are very time consuming and costly. This article aims to present empirical models using acoustic emission (AE) and cutting forces signals to predict entrance and exit burrs size in slot milling operation. These models can help estimating the burrs size without having to measure them. The machining tests were carried on Al 7075-T6 aluminum alloy using 3 levels of cutting speed, 3 levels of feed rate, 3 levels of cutting tool coating and 2 levels of depth of cut. Mathematical models were developed based on most sensitive AE parameters following statistical analysis, cutting forces and their interaction on predicting the entrance and exit burrs size. The proposed models correlate very well with the measured burrs size data.

Experimental and Numerical Investigation into Residual Stress During Turning Operation for Stainless Steel AISI 316

2020 ◽  
Vol 38 (12A) ◽  
pp. 1862-1870
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Main Role ◽  
Turning Operation ◽  
Aisi 316

RS (residual stresses) represent the main role in the performance of structures and machined parts. The main objective of this paper is to investigate the effect of feed rate with constant cutting speed and depth of cut on residual stresses in orthogonal cutting, using Tungsten carbide cutting tools when machining AISI 316 in turning operation. AISI 316 stainless steel was selected in experiments since it is used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, food and beverage industry. Four feed rates were selected (0.228, 0.16, 0.08 and 0.065) mm/rev when cutting speed is constant 71 mm/min and depth of cutting 2 mm. The experimental results of residual stresses were (-15.75, 12.84, 64.9, 37.74) MPa and the numerical results of residual stresses were (-15, 12, 59, and 37) MPa. The best value of residual stresses is (-15.75 and -15) MPa when it is in a compressive way. The results showed that the percentage error between numerical by using (ABAQUS/ CAE ver. 2017) and experimental work measured by X-ray diffraction is range (2-15) %.

Diamond tool wear monitoring by sensory analysis in milling of absolute black granite

2021 ◽  
pp. 095440542110406
Author(s):  
Sandro Turchetta ◽  
Luca Sorrentino ◽  
Gianluca Parodo
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Surface Machining ◽  
Diamond Tools ◽  
The Matrix ◽  
Cutting Force Components ◽  
Force Components ◽  
Natural Stones ◽  
And Performance

Diamond tools suitable for machining operations of natural stones can be divided into two groups: cutting tools, including blades, the circular blades and the wires, and the surface machining ones, involving mills and grinders, that can be of different shapes. For the stone sawing process, the most adopted tool type is the diamond mill, whose duration and performance are influenced by various elements such as: the mineralogical characteristics of the material to be machined; the working conditions such as the depth of cut, the feed rate and the spindle speed; the production process of the diamond segment and the characteristics of both the matrix and the diamond, such as the size, the type and the concentration of the diamonds and the metal bond formulation hardness. This work allows to indirectly assess the wear of sintered diamond tools by signal analysis (in time and frequency domain) of the cutting force components acquired in the process. The results obtained represent a fundamental step for the development of a sensory supervision system capable of assessing the tool wear and hence to modify the process parameters in process, in order to optimize cutting performance and tool life.

scholarly journals Simulation of plastic deformation and destruction in the process of chip formation

2018 ◽  
Vol 211 ◽  
pp. 17007
Author(s):  
Tanel Tärgla ◽  
Jüri Olt ◽  
Olga Liivapuu
Keyword(s):  
Plastic Deformation ◽  
Formation Process ◽  
Chip Formation ◽  
Rheological Model ◽  
Metal Cutting ◽  
Depth Of Cut ◽  
Key Factors ◽  
Local Zone ◽  
Complex Process ◽  
Relaxing Medium

Metal cutting is a complex process in which several mechanisms are at work simultaneously. The mathematical modelling allows carrying out research into the optimization of machining conditions. This work examines the simulation of chip formation during the process of cutting. The studies demonstrated that the chip formation process, taking into account the plastic deformation and destruction of metal in the local zone, is most appropriately represented by a rheological model in the form of a series connection of elasticductile- plastic relaxing medium of Ishlinskiy (reflecting the process of primary deformation of metal from the cut off layer) and the medium of Voigt with two elastic-dissipative elements (representing the process of deformation and frictions from the convergent shaving). The attained complex rheological model served as the basis for constructing a representative dynamic model for the chip formation process. The key factors that govern the chip formation have been taken into account, such as tool vibration frequency and amplitude, depth of cut, feed rate.

The Effect of Prior Cutting Conditions on the Shear Mechanics of Orthogonal Machining

1998 ◽  
Vol 120 (1) ◽  
pp. 13-20 ◽  
Author(s):  
R. Stevenson ◽  
D. A. Stephenson
Keyword(s):  
Material Properties ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cnc Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Prior History ◽  
Machining Conditions ◽  
The Difference

It has been proposed several times in the metal-cutting literature that the machining process is non-unique and that the instantaneous machining conditions depend on the prior machining conditions (e.g. depth of cut, rake angle etc.). To evaluate the validity of this concept, a series of experiments was conducted using a highly accurate CNC machining center. For these experiments, the machining conditions were changed during the course of an orthogonal cutting experiment in a repeatable manner and the measured forces compared as a function of prior history. Tests were conducted on several tempers of 1100 aluminum and commercial purity zinc to evaluate the effect of material properties on the machining response. It was found that the change in measured cutting forces which could be ascribed to prior machining history was less than 3 percent and that material properties, particularly work hardening response, had no discernible effect on the magnitude of the difference.

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