An improved analytical model of cutting temperature in orthogonal cutting of Ti6Al4V

Shan, Chenwei; Zhang, Xu; Shen, Bin; Zhang, Dinghua

doi:10.1016/j.cja.2018.12.001

Cited by 48 publications

(16 citation statements)

References 28 publications

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“…According to Smith's definition of orthogonal cutting heat source intensity, the total cutting heat source intensity Q is equal to the shear heat source Q shear of the primary deformation zone and the friction heat source Q friction of the secondary deformation zone. The cutting heat sources formula is as follows [29,30]:…”

Section: Molecular Dynamics (Md) Modelmentioning

confidence: 99%

Machinability and Surface Generation of Pd40Ni10Cu30P20 Bulk Metallic Glass in Single-Point Diamond Turning

et al. 2019

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Pd40Ni10Cu30P20 bulk metallic glass (BMG) is widely used in industrial fields due to its excellent oxidation resistance, corrosion resistance, and thermal stability. However, the lack of research on the machinability and cutting performance of BMG using single-point diamond turning (SPDT) limits its application for engineering manufacturing. In the present research, a series of turning experiments were carried out under different cutting parameters, and the machinability reflected by the quality of machined surface, chip morphology, and tool wear were analyzed. Based on the oxidation phenomenon of the machined surface, a molecular dynamics (MD) simulation was conducted to study the mechanism and suppression of the machined surface oxidation during the cutting. The results show that: (1) The Pd-based BMG had good machinability, where the machined surface roughness could go down to 3 nm; (2) irregular micro/nanostructures were found along the tool path on the outer circular region of the machined surface, which greatly affected the surface roughness; and (3) the cutting heat softened the workpiece material and flattened the tool marks under surface tension, which improved the surface quality. This research provides important theoretical and technical support for the application of BMG in optical mold manufacturing.

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Section: Molecular Dynamics (Md) Modelmentioning

confidence: 99%

Machinability and Surface Generation of Pd40Ni10Cu30P20 Bulk Metallic Glass in Single-Point Diamond Turning

et al. 2019

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“…These includes: process modelling, simulation and optimization, effective lubrication, redesign and reconfiguration of tool and the use of the hybrid machining process. These are to promote cost effectiveness, energy, material and environmental sustainability with improved productivity ( Dhananachezian & Kumar, 2011 ; Lee et al., 2012 ; Elshwain et al., 2013 ; Strano et al., 2013 ; Djavanroodi et al., 2013 ; Courbon et al., 2013 ; Rotella et al., 2014 ; Park et al., 2015 ; Kant and Sangwan, 2015 ; Kishawy et al., 2019 ; Shan et al., 2019 ). The quest for a sustainable manufacturing process whilst keeping a clean environment has necessitated manufacturers to develop and implement sustainable manufacturing processes with low carbon footprint and optimum energy and material consumption.…”

Section: Introductionmentioning

confidence: 99%

Review of life cycle models for enhancing machine tools sustainability: lessons, trends and future directions

Daniyan

Mpofu

Ramatsetse

et al. 2021

Heliyon

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The life cycle models are critical in the assessment of the performance of a product from the design phase to its end of life (EoL). With the quest for manufacturing sustainability with respect to energy, process, material, and environment friendliness as well as the clamour for circular economy which emphasizes zero tolerance for waste, there is a need for a critical review of the life cycle of machine tool employed for machining operations and product development. The objective of this study is to evaluate the efficient way of managing the machine tools throughout its lifecycle. Several studies have been conducted in analysing the life cycle of the machine tools and different strategies were employed for its design, manufacture, use, maintenance and recovery at the end of life. The common approach to ensure environmental sustainability was established when comparing the literature studied. From the articles reviewed 60% applied life cycle assessment (LCA) methodology to reduce energy consumption and enhance environmental sustainability, while 40% employed other assessment tools. In this study an integrated life cycle and cyber physical machine tool model is proposed.

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“…Chen et al 47 utilized a non-uniform moving heat source model to analyze the thermal problem in the machining of titanium alloy. Shan et al 48 proposed a modified analytical model for determining cutting tool temperature and heat partition along the tool-chip interface in orthogonal machining of titanium alloy Ti6Al4V. Shan et al 48 used a non-uniform heat intensity along the tool-chip interface in their thermal model but assumed lengths of the sticking friction zone ( l st ) and the sliding friction zone ( l sl ).…”

Section: Introductionmentioning

confidence: 99%

“…Shan et al 48 proposed a modified analytical model for determining cutting tool temperature and heat partition along the tool-chip interface in orthogonal machining of titanium alloy Ti6Al4V. Shan et al 48 used a non-uniform heat intensity along the tool-chip interface in their thermal model but assumed lengths of the sticking friction zone ( l st ) and the sliding friction zone ( l sl ). Recently, Curtis et al 49 reported that both contact patch and thermal energy partition are critical parameters in the assessment of residual stress formation when grinding Inconel 718 with conventional and super abrasives.…”

Section: Introductionmentioning

confidence: 99%

Thermal modelling of cutting tool temperatures and heat partition in orthogonal machining of high-strength alloy steel

Akbar

Arsalan

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Cutting temperatures and heat partition into the cutting tool are critical factors that significantly affect tool life and part accuracy during metal removal operations, especially in dry machining. Among many thermal modelling studies, uniform heat partition ratio, and/or uniform heat intensity along the tool-chip interface are frequently assumed. This assumption is not valid in actual machining and can lead to erroneous estimated results in the presence of sticking and sliding friction zones. Therefore, it is necessary to accurately predict the cutting tool temperature and heat partition during machining. This paper presents an analytical thermal modelling approach which considers the combined effect of the primary and the secondary heat sources and determines the temperature rise and non-uniform heat partition ratio along the tool-chip interface. Cutting tests were conducted on AISI/SAE 4140 high-strength alloy steel using carbide cutting tools over a wide range of cutting speeds. Cutting temperatures were measured experimentally using an infrared thermal imaging camera. Experimentally established sticking and sliding friction regions were used to evaluate non-uniform frictional heat intensity along the tool-chip interface. The temperature matching condition along the tool-chip interface leads to the solution of distributed non-uniform heat partition ratio by solving a set of linear equations through programming in MATLAB®. Experimental results show to be consistent well with those obtained from the thermal model, yielding a relative difference of predicted average tool-chip interface temperature from −0.8% to 6.3%. It is found that average heat partition into the cutting tool ( RT) varies from 35% down to 15% for the entire range of cutting speeds. These results suggest that, to address the thermal problem in metal cutting, the research and development of tooling should also focus on reducing friction on the tool rake face in addition to the contribution of the combined effect of primary and secondary heat sources on temperature rise at the tool-chip interface.

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An improved analytical model of cutting temperature in orthogonal cutting of Ti6Al4V

Cited by 48 publications

References 28 publications

Machinability and Surface Generation of Pd40Ni10Cu30P20 Bulk Metallic Glass in Single-Point Diamond Turning

Machinability and Surface Generation of Pd40Ni10Cu30P20 Bulk Metallic Glass in Single-Point Diamond Turning

Review of life cycle models for enhancing machine tools sustainability: lessons, trends and future directions

Thermal modelling of cutting tool temperatures and heat partition in orthogonal machining of high-strength alloy steel

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