Analytical Modeling of Cutting Forces and Technological Parameters Interrelation when Grinding Shafts' Ends by a Grinding Wheel End on Circular Grinding Machines

Abrasive processing remains one of most demanded for hardened steels parts. Grinding of end surfaces of machines parts has become widespread due to the fact that it allows processing heat-treated surfaces more efficiently than turning and also correcting the surface geometry. This processing type is used almost mainly for finish processing operations of shafts ends, bearing rings, gears, etc. However, there is still no mathematical model for this processing type, which would satisfy most of the main technological parameters. In this article a mathematical model of the cutting force when grinding the shaft end by the grinding wheel end on circular grinding machines is obtained. Processing schemes for this grinding type are given and the calculated graph of the cutting force according to the obtained mathematical model is shown.

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Influence of Grinding Wheel Dressing on the Roughness of Final Surface and Cutting Force during GGG60 Grinding

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.686.218 ◽

2016 ◽

Vol 686 ◽

pp. 218-223 ◽

Cited By ~ 5

Author(s):

Martin Novák ◽

Natasa Naprstkova ◽

Hiroshi Kasuga

Keyword(s):

Surface Roughness ◽

Impact Assessment ◽

Cutting Force ◽

Surface Integrity ◽

Cutting Forces ◽

Geometric Shape ◽

Grinding Wheel ◽

Final Surface

Dressing of grinding wheel is important value, which can influence final surface. Therefore, it is necessary to address this issue some attention. Dressing is used for sharpening of clogged and blunted grinding wheel and adjustement of their geometric shape. The article deals with one of the experiments that are carried out in this area at FPTM JEPU in Ústí nad Labem. Experiments refer specifically to impact assessment of dressing size on the final selected values of surface integrity. Within the article, the assessment covered the surface roughness Ra, Rz and Rt. At the same time were also scanned using a dynamometer Kistler components of the cutting forces and even here it was possible to observe the influence of the dressing size of the grinding wheel on these values.

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Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽

10.3390/met10060840 ◽

2020 ◽

Vol 10 (6) ◽

pp. 840 ◽

Cited By ~ 3

Author(s):

Rashid Ali Laghari ◽

Jianguang Li ◽

Mozammel Mia

Keyword(s):

Mathematical Model ◽

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Desirability Function ◽

Interactive Effect ◽

Cutting Speed ◽

Experimental Results ◽

Machining Process ◽

Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

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An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials

Applied Sciences ◽

10.3390/app11093888 ◽

2021 ◽

Vol 11 (9) ◽

pp. 3888

Author(s):

Renke Kang ◽

Jinting Liu ◽

Zhigang Dong ◽

Feifei Zheng ◽

Yan Bao ◽

...

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

Experimental Studies ◽

Brittle Materials ◽

Grinding Force ◽

Grinding Wheel ◽

Force Model ◽

Cutting Force Model ◽

Fillet Radius ◽

Hard And Brittle Materials

Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

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Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

SN Applied Sciences ◽

10.1007/s42452-021-04689-z ◽

2021 ◽

Vol 3 (7) ◽

Author(s):

Rashid Ali Laghari ◽

Jianguang Li

Keyword(s):

Mathematical Model ◽

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Positive Response ◽

Cutting Speed ◽

Machining Process ◽

Depth Of Cut ◽

Force Model ◽

Sic Particles

Abstract In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

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Adaptive Cutting Force Control with a Hybrid Axis System

International Journal of Automation Technology ◽

10.20965/ijat.2013.p0378 ◽

2013 ◽

Vol 7 (4) ◽

pp. 378-384 ◽

Cited By ~ 2

Author(s):

Berend Denkena ◽

◽

Felix Flöter

Keyword(s):

Cutting Force ◽

Force Control ◽

Cutting Forces ◽

Major Effect ◽

Machining Process ◽

Surface Geometry ◽

Milling Machines ◽

Implementation Costs ◽

Estimation And Control ◽

And Control

Cutting forces have a major effect on the results of a machining process. High loads on the tool can lead to surface geometry and surface roughness that are less than optimal. However, due to its high implementation costs, cutting force control is not often used on milling machines. The paper presents a new approach by integrating a hybrid axis system in the force control loop. This offers a more dynamic and accurate way to influence cutting forces, but it also results in a more complex control problem. Therefore, how the nonlinear and time-varying characteristics of the cutting process can be modeled and considered for an automated operation is comprehensively shown. The interaction of process estimation and control is demonstrated with a PID-Control structure. Experimental results are presented.

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Generic Mathematical Model for Efficient Milling Process Simulation

Mathematical Problems in Engineering ◽

10.1155/2015/875045 ◽

2015 ◽

Vol 2015 ◽

pp. 1-10 ◽

Cited By ~ 1

Author(s):

Hilde Perez ◽

Eduardo Diez ◽

Juan de Juanes Marquez ◽

Antonio Vizan

Keyword(s):

Mathematical Model ◽

Cutting Force ◽

Process Simulation ◽

Cutting Forces ◽

Metal Cutting ◽

Chip Thickness ◽

Machining Process ◽

Force Estimation ◽

Peripheral Milling ◽

Simulation And Optimization

The current challenge in metal cutting models is to estimate cutting forces in order to achieve a more accurate and efficient machining process simulation and optimization system. This paper presents an efficient mathematical model for process simulation to evaluate the cutting action with variable part geometries of helical cutters and predict the cutting forces involved in the process. The objective of this paper has been twofold: to improve both the accuracy and computational efficiency of the algorithm for cutting force estimation in peripheral milling. Runout effect and the real tool tooth trajectory are taken into account to determine the instantaneous position of the cutting flute. An expression of average chip thickness for the engaged flute in the cut is derived for cutting force calculations resulting in a more efficient process simulation method in comparison with previous models. It provides an alternative to other studies in scientific literature commonly based on numerical integration. Experiments were carried out to verify the validity of the proposed method.

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Analysis of cutting forces during in-cut and out-cut milling of EN AC-AlSi10Mg cast aluminum alloy

Mechanik ◽

10.17814/mechanik.2018.10.148 ◽

2018 ◽

Vol 91 (10) ◽

pp. 871-873

Author(s):

Józef Kuczmaszewski ◽

Paweł Pieśko ◽

Magdalena Zawada-Michałowska

Keyword(s):

Aluminum Alloy ◽

Cutting Force ◽

Cutting Forces ◽

High Speed ◽

Cutting Speed ◽

Depth Of Cut ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Technological Parameters ◽

High Speed Cutting

The analysis of cutting forces during in-cut and out-cut milling of EN AC-AlSi10Mg cast aluminum alloy was presented. The research included measurement of the components of the total cutting force: Ff, Fp and Fc (Fx, Fy, Fz respectively) and determination of their amplitudes at a constant feed per tooth value and the adopted variable technological parameters, i.e.: depth of cut ap, milling width ae and cutting speed vc. Based on the obtained results, it was found that along with the increase in the depth of cut and the milling width, the values of selected components and their amplitudes increase for both in-cut and out-cut milling. During rise of cutting speed, it was observed that the components of the total cutting force increase to the speed vc = 450 m/min, then their values begin to decrease. This is related to the transition from conventional machining to the range of High Speed Cutting. It is important that higher values of cutting forces were noted in the case of out-cut milling instead of in-cut milling.

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