Conservation law of surface roughness in single point diamond turning

Abstract

Carbon Fiber-Reinforced by Plastic (CFRP) is now commonly used in the aircraft industry. The main challenge is to manufacture this difficult-to-cut work material, considering its quality criteria and economical aspects. Drilling is the main machining operation required for the assembly of the aircraft structure. In this paper, results are presented and discussed regarding exit delamination studied at a local scale. Because of the anisotropic properties of CFRP, the fiber cutting modes change with the composite sequence combined with the drill revolution parameters. The local feed forces generated by the cutting edge on the hole bottom may be correlated with delaminating aspects. A posttreatment method is proposed to analyze precisely these feed force and cutting torque distributions. Appropriate ply sequences are identified in order to limit the mechanical load concentration and the risk of delamination or uncut fibers n Corresponding author.

Experimental investigation on finish intermittent turning of UNS M11917 magnesium alloy under dry machining

“…This effect is more likely when using large tool nose radius in combination with small depths of cut and feed rates [39]. The combination of low depths of cut and feed rates leads to small undeformed chip thickness comparable to tool nose radius and, in this case, a part of the surface roughness values depends on the undeformed chip thickness [40]. Moreover, in Fig.…”

Recent Advances in Micro/Nano-cutting: Effect of Tool Edge and Material Properties

“…Ng et al [83] investigated surface roughness in diamond cutting of aluminum 2075-T6 and found that the generated surface at an UCT smaller than the tool edge radius is rougher than that with larger UCT. The phenomenon that the cutting-induced surface roughness always deviates from the theoretical value could be partly attributed to the effect of the cutting tool edge [156]. The elastic recovery and the side flow of materials are two factors affected by tool edge and further influence the surface roughness.…”

“…Results showed that the elastic recovery for the sharp tool is lower than for the blunt tool and the variation of elastic recovery is in coherence with the change of surface roughness [160]. To predict the surface roughness in single point diamond turning, Zong et al [156] introduced an additional term to the roughness formulation proposed by Grezesik [161]. It is formulated as…”

“…The side flow of material has been taken into account to predict the machined surface roughness [156,162,164,169]. In 2006, Liu et al [164] established a relationship between the roughness due to side flow R p and the rheological factor x, which is formulated as…”

“…In 2014, Zong et al [156] introduced a scale coefficient k 3 relating to the side flow to the surface roughness prediction formulation. In determining the value of the coefficient k 3 , the feed rate and tool nose radius are considered.…”