Design of a computer aided quick-stop device for study of dead metal zone formation

Ozturk, Sabri; Altan, Erhan

doi:10.1590/s1678-58782012000400011

Cited by 9 publications

(4 citation statements)

References 18 publications

(16 reference statements)

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“…They discovered that the chip removal procedure is not considerably affected by a stagnant material zone beneath the chamfer angle. Ozturk [ 19 ] employed a quick stop device to collect chip root samples that are typical of the deformation occurring under dynamic cutting scenarios. Additionally, they did a metallographic analysis on selected specimens to examine the microstructure and creation of the dead metal zone.…”

Section: Introductionmentioning

confidence: 99%

Study on the Formation Mechanism of Cutting Dead Metal Zone for Turning AISI4340 with Different Chamfering Tools

Wang

Zhang

et al. 2022

Micromachines

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Tools with chamfered edges are often used in high speed machining of hard materials because they provide compelling cutting toughness and reduced tool wear. Chamfered tools are also responsible for the dead metal zone (DMZ). Through numerical simulation of orthogonal cutting with AISI 4340 steel, this paper examines the mechanism of the DMZ, the cutting speed, the impacts of the chamfer angle, and the coefficient of friction on the generation of the DMZ. The analysis is based upon the Arbitrary Lagrangian-Eulerian (ALE) finite element method (FEM) for the continuous process of chip formation. The different chamfered angles, cutting speeds, and friction coefficient conditions are utilized in the simulation. The research demonstrates that a zone of trapped material called DMZ has been formed beneath the chamfer and serves as an effective cutting edge of the tool. Additionally, the dead metal zone DMZ becomes smaller while the cutting speed increases or the friction coefficient decreases. The machining forces rise with increasing chamfer angles, rise with increasing friction coefficients, and fall with increasing cutting speed in both the cutting and thrust directions. In this paper, the effect of different chamfering tools on AISI 4340 steel using carbide tools in the simulation environment is studied. It has certain reference significance for studying the formation mechanism of the dead zone of difficult-to-machine materials such as AISI4340 and improving the processing efficiency and workpiece surface quality.

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Section: Introductionmentioning

confidence: 99%

Study on the Formation Mechanism of Cutting Dead Metal Zone for Turning AISI4340 with Different Chamfering Tools

Wang

Zhang

et al. 2022

Micromachines

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“…For instance, in shaping, an electromagnetic QSD was fabricated by Wu et al 20 Griffiths 21 invented a QSD for deep drilling, however, in grinding readers are referred to the research works of G€ ottsching et al 22 and Ghosh et al 23 Readers are referred also to other more recent research works dealing with designing and manufacturing of new QSDs and the study of chip formation for various workpiece materials. For instance, Computer Aided Quick Stop Device (CAQSD) employing a servo motor is developed by Ozturk et al 24 for the study of dead metal zone formation in brass workpiece material. An explosive quick-stop device has been invented by Linjiang et al 25 to study the chip formation mechanism in turning of Ti2AlNb intermetallic alloy.…”

Section: Introductionmentioning

confidence: 99%

A new quick-stop device to study the chip formation mechanism in metal cutting: Computational and experimental investigation

Mhamdi

Rajhi

Boujelbene

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Understanding the chip formation mechanisms during machining is an important factor to facilitate the choice of cutting tools and machining parameters. Despite the appearance of new sophisticated methods and advanced equipment, the technique so called quick-Stop Test (QST) remains efficient, less costly, and easier to apply in the investigation of chip formation in cutting process. In present paper a new Quick-Stop Device QSD is designed, numerically simulated, implemented, and tested. The reformed QST technique uses a QSD device which operates on the modified Charpy pendulum. Accordingly, design of new QSD is presented and deeply described, and 2D FE modeling of the new QST, including the application of the appropriate boundary conditions, has been carried out. Moreover, chip formation and morphology for different cutting conditions have been effectively simulated. Subsequently, quick stop cutting operations including metal cutting tests of high alloyed tool steel (AISI D2) using fabricated new QSD are performed. Preliminary results of quick-stop experiment from current investigation prove the effectiveness of the new designed QSD in matter of rigidity, safety, and absence of vibration, while providing a fast set up time and allowing extremely short workpiece-cutting tool separation time and guarantee the generation of chip with its root. The photomicrographs of chip root samples gathered from hard metal cutting experiments including various cutting speeds machining conditions, enables clear observation of segmented chip formation mechanisms, thereby, highly promising the new designed QSD for the purpose of investigation of the different cutting parameters influencing the chip formation and morphology.

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“…[7] or planing as in Ref. [8]; few works have been performed in drilling using such equipment. After a literature review, only Dolinšek focuses on the austenitic stainless steel drilling operation and has only analyzed the effect of the cutting conditions (cutting velocity and the feed) on the strain hardening evolution [4].…”

Section: Introductionmentioning

confidence: 99%

Investigations on Strain Hardening During Cutting of Heat-Resistant Austenitic Stainless Steel

Arif

Fromentin

Rossi

et al. 2020

Journal of Manufacturing Science and Engineering

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This study presents a novel analysis of the machined subsurface layer formation dealing with strain hardening phenomenon which results from complex mechanisms due to cutting edge multiple passes in drilling. On the one hand, the hardened layer during drilling is characterized in relation with the local cutting geometry and thanks to a quick-stop device (QSD) to suddenly interrupt the operation. Micro hardness is used to determine the hardened thickness of the machined subsurface layers along the local cutting edge geometry. On the other hand, orthogonal cutting performed with a complex self-designed planing experiment is used to investigate in details the hardening accumulation aspects. Then, dedicated methodologies are proposed to quantify the strain hardening as well as the incremental plastic strain generated by consecutive tool passes. In addition to the subsurface hardness evolution, the work material strain is observed during the steady-state cutting process thanks to the high-speed camera. The digital image correlation technique is exploited to analyze not only the plastic strain remaining on the workpiece after the cut but also the effect of the incremental plastic strain generated by the consecutive planing passes as the cutting edges in drilling do. One of the outcomes is that the hardened layer thickness can reach from two to three times the cut thickness in drilling or in planing. As a consequence, this work demonstrates that the cutting process affects itself by hardening. Thus, the studied austenitic stainless steel in such a way that this last is never cut in its initial state.

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Design of a computer aided quick-stop device for study of dead metal zone formation

Cited by 9 publications

References 18 publications

Study on the Formation Mechanism of Cutting Dead Metal Zone for Turning AISI4340 with Different Chamfering Tools

Study on the Formation Mechanism of Cutting Dead Metal Zone for Turning AISI4340 with Different Chamfering Tools

A new quick-stop device to study the chip formation mechanism in metal cutting: Computational and experimental investigation

Investigations on Strain Hardening During Cutting of Heat-Resistant Austenitic Stainless Steel

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