Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Monková, Katarína; Monka, Peter; Sekerakova, Adriana; Hružík, Lumír; Bureček, Adam; Urban, Marek

doi:10.3390/met9060698

Cited by 9 publications

(16 citation statements)

References 44 publications

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“…In the preliminary research of the authors [13], where the changes in temperature and microhardness of a chip root were evaluated, the angle of tool cutting edge inclination appeared to be an insignificant parameter. However, regarding changes in the chip shape, the angles of tool cutting edge inclination λ s and tool cutting edge κ r were the most important parameters.…”

Section: Discussionmentioning

confidence: 97%

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Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Monková

Monka

Sekerakova

et al. 2019

Metals

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One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in case of the so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency. The article deals with the chip root evaluation of two EN C45 and EN 16MnCr5 steels, focusing on the shear angle measuring and built-up edge observation as important factors influencing the machining process, because a repeated formation and dislodgement of built-up edge unfavorably affects changes in the rake angle, causing fluctuation in cutting forces, and thus inducing vibration, which is harmful to the cutting tool. Consequently, this leads to surface finish deterioration. The planing was selected as a slow-rate machining operation, within which orthogonal and oblique cutting has been used for the comparative chips' root study. The planned experiment was implemented at three levels (lower, basic, and upper) for the test preparation and the statistical method, and regression function was used for the data evaluation. The mutual connections among the four considered factors (cutting speed, cutting depth, tool cutting edge inclination, and rake angle) and investigated by the shear angle were plotted in the form of graphical dependencies. Finally, chips obtained from both steels types and within both cutting methods were systematically processed from the microscopic (chip root) and macroscopic (chip pattern) points of view.Metals 2019, 9, 956 2 of 27 of a machined surface are in many cases not achievable by mechanical working or casting processes, because the surfaces of the parts are adversely affected. This is why machining is needed.[3] Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency.One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in the case of so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Chips at the machining are formed due to tearing and shearing, the workpiece material adjacent to the tool face is compressed and a crack runs ahead of the cutting tool and towards the body of the workpiece. Cutting takes place intermittently and there is no movement of the w...

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Section: Discussionmentioning

confidence: 97%

“…However, orthogonal cutting is only a particular case of oblique cutting, such that any analysis of orthogonal cutting can be applied to oblique cutting. Oblique cutting is a common type of three-dimensional cutting used in the machining process [13].…”

Section: State Of the Artmentioning

confidence: 99%

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Monková

Monka

Sekerakova

et al. 2019

Metals

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“…Combined (experimental, analytical, numerical model, etc.) [3,[6][7][8][12][13][14][15][16][18][19][20]22,25,26] As can be readily observed, the experimental and empirical approach is the dominant methodology of failure investigation. In addition, the emergence of numerical simulation, using finite element modeling (FEM), tends to be very popular in the prediction of material behavior and potential failure prevention.…”

Section: Contributionsmentioning

confidence: 99%

“…Reference Structural and pipeline steels [1,5,9,13,16,20,22,27] Cast iron [14,19] Special resistance and stainless steels [3,4,9,11,17,18,21,23,24] Wear resistant coatings and surface layers [24,27]…”

Section: Materials Typementioning

confidence: 99%

Failure Mechanisms in Alloys

2020

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“…For a long time, people have been committed to the research on rules of change in chip morphology and on modeling techniques under different processing conditions and have made fruitful achievements. For instance, through his experimental observation of chip morphology in the machining of EN16MnCr5 Steel with the straight double-edged tool, Monkova et al [11] found that the larger the cutting thickness and the edge inclination angle, the longer the chip. Polvorosa et al [12] compared the tool wear and its corresponding chip morphology when turning Alloy 718 with cemented carbide inserts.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Bifurcation Set Equation Modeling of Chip-Splitting Catastrophe

You¹,

Xu²,

Zhu³

et al. 2021

Preprint

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This paper presents the methods of designing experiments for observation of the critical conditions of chip-splitting catastrophe (CSC) based on the dichotomy principle and the methodology of modelling CSC with a bifurcation set equation on the basis of catastrophe theory. 355 groups of experiments are carried out for observing critical conditions of CSC in the symmetrical straight double-edged cutting. It is found that the occurrence of CSC is of obvious regularity. Besides, the specific cutting force is reduced by a maximum of 64.68% after CSC. The bifurcation set equation is established, which can predict the critical conditions of CSC in the symmetrical cutting with a straight double-edged tool with any combinations of cutting edge angles and rake angles. With verification, the predicted values of the critical cutting thickness of CSC based on the established equation are in good agreement with experimental values and yield an average absolute prediction error of 5.34%, which is satisfactorily low. This study lays the groundwork for energy-saving optimization of tool structure and process parameters through reasonable utilization of CSC.

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Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Cited by 9 publications

References 44 publications

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Failure Mechanisms in Alloys

Experimental Investigation and Bifurcation Set Equation Modeling of Chip-Splitting Catastrophe

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